Use of intermittent energy in the production of chemicals

ABSTRACT

A chemical synthesis plant comprising: one or more reactors configured for producing, from one or more reactants, a process stream comprising at least one chemical product; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor; and/or a product purification system configured to separate the at least one chemical product from reaction byproducts, unreacted reactants, or a combination thereof within the process stream, wherein the chemical synthesis plant is configured such that a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof utilized via the one or more reactors, the feed preparation system, the product purification system, or a combination thereof is provided from an intermittent energy source (IES).

TECHNICAL FIELD

The present disclosure relates to the use of an intermittent energy source IES (which may be a non-carbon-based and/or a renewable energy source) in the production of chemicals; more particularly, the present disclosure relates to the electrification of a chemical synthesis plant utilizing electricity from an IES; still more particularly, the present disclosure relates to systems and methods of operating a chemical synthesis plant with an IES.

BACKGROUND

Chemical synthesis plants are utilized to provide a variety of chemicals. Often, a dedicated fuel is burned or ‘combusted’ to provide heat of reaction for chemical synthesis, energy to heat one or more process streams, energy to vaporize liquids (e.g., boil water used as a diluent), energy to do work (e.g., drive a compressor or pump), or energy for other process operations throughout the chemical synthesis plant. Such burning or combustion of fuels results in the production of flue gases, which can be harmful to the environment, and also results in a loss of energy efficiency of the process. Likewise, steam is often conventionally utilized as a plant-wide heat and/or energy transfer fluid within chemical synthesis plants. The steam utilized for the heat and/or energy transfer is often produced via the combustion of a fuel, resulting in the production of additional flue gas and further energy efficiency losses during the chemical synthesis. Additionally, the use of a material that could otherwise be utilized as a reactant for combustion as a fuel also reduces an amount of the desired chemical product produced in the chemical synthesis plant from a given amount of the material. Accordingly, a need exists for enhanced systems and methods of chemical synthesis whereby an amount of fuels, especially fossil fuels, burned to provide energy is reduced or eliminated. Desirably, such systems and methods also provide for an increase in energy efficiency and/or a decrease in emissions, such as emissions of greenhouse gases (GHG), by the chemical synthesis plant.

SUMMARY

Herein disclosed is a chemical synthesis plant comprising: one or more reactors configured for producing, from one or more reactants, a process stream comprising at least one chemical product; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor; and/or a product purification system configured to separate the at least one chemical product from reaction byproducts, unreacted reactants, or a combination thereof within the process stream, wherein the chemical synthesis plant is configured such that a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof utilized via the one or more reactors, the feed preparation system, the product purification system, or a combination thereof is provided from an intermittent energy source (IES).

Also disclosed herein is a chemical synthesis plant configured for operation utilizing electricity from a renewable intermittent energy source (IES) to provide a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

FIG. 1 shows a conceptual diagram of a typical prior art chemical process;

FIG. 2 shows a conceptual diagram of a chemical process that can be powered by renewable intermittent energy, according to embodiments of this disclosure;

FIG. 3 shows a block flow diagram of a generalized chemical synthesis plant I that can be powered by a renewable intermittent energy source (IES), according to embodiments of this disclosure;

FIG. 4 shows a schematic of a chemical synthesis plant II that can be powered by a renewable intermittent energy source (IES), according to embodiments of this disclosure;

FIG. 5A is a schematic of a system IIIA for storing energy via compression, according to embodiments of this disclosure;

FIG. 5B is a schematic of a system IIIB for storing energy via cooling, according to embodiments of this disclosure;

FIG. 5C is a schematic of a system IIIC for storing energy via hydrogen, according to embodiments of this disclosure; and

FIG. 5D is a schematic of a system IIID for storing energy via heating, according to embodiments of this disclosure.

FIG. 6 shows operating parameters for an olefin synthesis process VII electrified as per an embodiment of this disclosure and presented in Examples 1 and 2.

FIG. 7 shows operating parameters for an ammonia synthesis process XII electrified as per an embodiment of this disclosure and presented in Examples 3 and 4.

FIG. 8 shows operating parameters for a methanol synthesis process X/XI electrified as per an embodiment of this disclosure and presented in Examples 5 and 6.

DETAILED DESCRIPTION

It should be understood at the outset that although an illustrative implementation of one or more embodiments are provided below, the disclosed compositions, methods, and/or products may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated hereinbelow, including the exemplary designs and implementations illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.

While the following terms are believed to be well understood by one of ordinary skill in the art, the following definitions are set forth to facilitate explanation of the presently disclosed subject matter. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs.

As utilized herein, an ‘intermittent energy source’ or ‘IES’ is any source of energy that is not continuously available for conversion into electricity and outside direct control because the used energy cannot be stored or is economically undesirable. The availability of the intermittent energy source may be predictable or non-predictable. A renewable intermittent energy source is an intermittent energy source that is also a source of renewable energy, as defined hereinbelow. ‘Intermittent electricity’ refers to electricity produced from an IES.

As utilized herein, ‘renewable energy’ and ‘non-fossil based energy (E_(NF))’ includes energy derived from a sustainable energy source that is replaced rapidly by a natural, ongoing process, and nuclear energy. Accordingly, the terms ‘renewable energy’ and ‘non-fossil based energy (E_(NF))’ refer to energy derived from a non-fossil fuel based energy source (e.g., energy not produced via the combustion of a fossil fuel such as coal or natural gas), while ‘non-renewable’ or ‘fossil based energy (E_(F))’ is energy derived from a fossil fuel-based energy source (e.g., energy produced via the combustion of a fossil fuel). Fossil fuels are natural fuels, such as coal or gas, formed in the geological past from the remains of living organisms. Accordingly, as utilized herein, ‘renewable’ and ‘non-fossil based energy (E_(NF))’ include, without limitation, wind, solar power, water flow/movement, or biomass, that is not depleted when used, as opposed to ‘non-renewable’ energy from a source, such as fossil fuels, that is depleted when used. Renewable energy thus excludes fossil fuel based energy (E_(F)) and includes biofuels.

As utilized herein, ‘non-carbon based energy (E_(NC))’ is energy from a non-carbon based energy source (e.g., energy not produced via the combustion of a carbon-based fuel such as a hydrocarbon), while carbon based energy (E_(r)) is energy from a carbon-based energy source (e.g., energy produced via the combustion of a carbon-based fuel such as a hydrocarbon). Nuclear energy is considered herein a renewable, non-fossil (E_(NF)) based energy and a non-carbon based energy (E_(NC)). Carbon-based energy (E_(C)) can thus be renewable (e.g., non-fossil fuel based) or non-renewable (e.g., fossil fuel-based). For example, various carbon-based biofuels are herein considered renewable, carbon-based energy sources.

As utilized herein, ‘renewable electricity’ indicates electricity produced from a renewable energy source, while ‘non-renewable electricity’ is electricity produced from a non-renewable energy source. As utilized herein ‘non-carbon based electricity’ indicates electricity produced from a non-carbon based energy source, while ‘carbon-based electricity’ is electricity produced from a carbon-based energy source.

For example, in embodiments, renewable electricity and/or heat throughout the herein-disclosed chemical synthesis plant can be provided by the combustion of renewable hydrocarbons that come from renewable (e.g., biological) sources. For example, renewable electricity can, in embodiments, be produced via the combustion of an E_(NF)/E_(C) energy source comprising methane produced in a digester fed with agricultural wastes. Likewise, in embodiments, an E_(NF)/F_(C) energy source comprising synthesis gas produced using short cycle carbon waste materials can be utilized as a fuel (e.g., combusted to produce renewable electricity and/or heat). Desirably, the carbon dioxide generated by such combustion is recaptured (e.g., by the growth of a new crop).

As utilized herein, ‘externally’ combusting a fuel refers to combusting a fuel outside of a reactor, e.g., in a furnace. Combustion as a part of the primary reaction (e.g., combustion which takes place with reforming in autothermal reforming (ATR)) would not be considered ‘externally’ combusting. As utilized herein, a ‘dedicated’ fuel is a fuel or portion of a feed stream introduced solely to provide fuel value (e.g., combustion heat) and not be converted into product.

As utilized herein, heat transfer steam (S_(HT)) indicates steam produced solely or primarily as an energy or heat transfer medium (e.g., steam not utilized as a diluent and/or reactant).

As utilized herein, ‘net’ heat input or removal refers to heat input or removal that results in primary energy consumption, e.g., heat input or removal not provided from another section or stream of the plant, e.g., not provided via heat exchange with another process stream. Similarly, ‘net’ energy refers to energy that results in primary energy consumption, e.g., energy not provided from another section or stream of the plant, e.g., thermal energy not provided via heat exchange with another process stream.

As utilized herein, ‘powering’ indicates supplying with mechanical and/or electrical energy.

As utilized herein, ‘heating’ indicates supplying with thermal energy. As utilized herein ‘cooling’ indicates the removal of thermal energy therefrom. As utilized herein, ‘direct’ heating or cooling refer to heating or cooling without the use of a heat transfer medium/fluid; ‘indirect’ heating or cooling refer to heating or cooling via a heat transfer medium/fluid.

As utilized herein, ‘most’ or ‘a majority’ indicates more than 50% or more than half.

As utilized herein, a ‘desired’ parameter (e.g., desired temperature) may refer to an intended or target value for the parameter, for example a predetermined value such as a set-point value used for process control.

Amount of electricity consumed: References to consumption of electricity may refer to a rate at which electricity is used (e.g., in MW), as measured at a particular location. For example, a rate may be calculated at the boundary of each electrified furnace or at an overall olefin synthesis plant boundary. This calculation may consider all electricity used within that location.

Flue gas: A mixture of gases that may be produced by the burning of fuel or other materials in a power station and/or industrial plant, where the mixture of gases may be extracted via ducts.

Flue gas heat recovery: Flue gas heat recovery may refer to the extraction of useful thermal energy from hot flue gases, for example by passing said hot flue gas over one or more heat exchangers to raise the temperature of a cooler process fluid and/or change the phase of said fluid (e.g., boil water to raise steam). Any energy remaining in the flue gas after any flue gas heat recovery may be termed flue gas (energy) loss. A flue gas heat recovery section may be the equipment and corresponding location of said equipment used to recover flue gas heat. A lack of flue gas heat recovery section may mean there is no equipment or area where heat is recovered from hot flue gases.

Convection section: A convection section may be a portion of a furnace (e.g., steam cracking furnace or reforming furnace) where heat is recovered from hot flue gases by convective heat transfer. A lack of convection section may mean that there is no equipment or area where heat is recovered by convective heat transfer from hot flue gases.

“Steam-free” or “Substantially Steam-free”: “Steam free” may refer to a process where steam is not used to transfer energy from one process operation to another, or to bring energy into the process from outside. “Substantially steam-free” means that the use of steam to transfer energy from one process operation to another or to bring energy into the process from outside has been minimized such that the sum of all energy transfers using steam amount to less than approximately 10%, approximately 20%, or approximately 30% of the net energy provided. Steam used as a reactant, a diluent, obtained as a product, or directly mixed with a process stream may be termed “process steam” and is not included in this definition.

Primary energy transfer medium: A primary energy transfer medium may be a substance that is used to move energy in the form of thermal energy from one process operation to another, or to bring energy into a process. Note that a substance may serve more than one purpose in a process such as acting as a reactant or reaction diluent whilst also acting as a medium to transfer heat from one process operation to another. In such instances, the use of steam as reactant or diluent may be considered primary and the effect of also transferring heat may be considered secondary.

Resistive heating: Resistive heating may be heating by means of passing electric current through resistive units.

Inductive heating: Induction heating may be a process of heating an electrically conducting object (usually a metal) by electromagnetic induction.

Radiant heating: Radiant heating may be a process of heating an object via radiation from one or more hotter objects.

Externally combusting: Externally combusting may mean burning fuel to generate heat and transferring this heat to a process fluid across a surface (e.g., a tube wall) such that combustion products do not mix with the process fluid.

Thermoelectric device: A thermoelectric device may be a device for the direct conversion of temperature differences to electric voltage (or vice versa) across a thermocouple.

Isothermal operation: Isothermal operations may be operations at a constant temperature.

Isothermal operation can keep temperature within 0.5%, 1%, 2%, 3%, 4%, 5% up to 10% of the predetermined operation temperature.

Convective heat transfer: Convective heat transfer may be the movement of heat from one place to another by the movement of a fluid or fluids.

Although the majority of the above definitions are substantially as understood by those of skill in the art, one or more of the above definitions can be defined hereinabove in a manner differing from the meaning as ordinarily understood by those of skill in the art, due to the particular description herein of the presently disclosed subject matter.

As utilized herein, reference to when IES is ‘available’ includes when the IES can be obtained and/or when the IES can be obtained at an economical price. That is, for brevity, saying, ‘when the IES is available’ is intended to include, ‘when the IES is available and/or is economically desirable’.

FIG. 1 shows a conceptual diagram of a typical traditional chemical process. The goal of this process is to convert feed A into product B, although often some byproducts (indicated as stream C) are also produced.

The unit operations used to effect this transformation require significant amounts of energy. Conventionally, this energy is primarily supplied by burning a fuel, often natural gas, to generate heat, denoted in FIG. 1 as ΔH_(c) (e.g., heat of combustion). This results in the undesirable production and emission of carbon dioxide (CO₂). Additional energy may be supplied by the heat of reaction, ΔH_(f), if the reaction is exothermic; if the reaction is endothermic, an additional amount of energy equal to ΔH_(r) will need to be added. The total energy balance may also be affected if some byproducts are burned to produce energy, indicated as ΔH_(bp). However, many chemical processes, even those involving exothermic reactions, are net energy consumers and thus require an external source of energy (typically provided by a hydrocarbon fuel(s)) to provide net process energy.

Electricity is usually only a small external input into most chemical production processes.

Internal electrical requirements, such as for lighting or control, are usually so small as to be negligible, and in those few processes which require large amounts of electricity, for example, electrochemical reactors (e.g., the chlor-alkali process to make chlorine (Cl₂) and sodium hydroxide (NaOH)), this electricity is commonly generated within the plant boundaries by the combustion of hydrocarbons, and, even when not generated within the plant boundaries, if the electricity is obtained by the combustion of hydrocarbons rather than renewably, such use of electricity is equivalent in terms of energy efficiency and CO₂ emissions to on-site production of the electricity via hydrocarbon combustion.

Within most chemical production processes, energy consumption can conveniently be divided into three main categories. In the first such broad category, referred to herein as first category C1, heat is supplied directly as thermal energy by the combustion of a fuel (e.g., natural gas/fossil fuels) in a furnace. (As utilized, here, ‘directly’ indicates the absence of an intermediate heat transfer medium, such as steam.) These furnaces are often operated at high temperature and require large heat fluxes. The energy efficiency of such furnaces is limited by the heat losses in the furnace flue gas. Even where these heat losses are minimized by the cooling of the flue gas to recover energy, for example to generate steam or provide process heating, the conversion of the chemical energy contained in the fuel to usable thermal energy generally does not exceed 85 to 90%, even with substantial investment and loss of design and operating flexibility.

The second broad category, referred to herein as second category C2, of energy consumption in chemical processes comprises the heating of various chemical streams, primarily either to raise the temperature thereof to a desired reaction temperature or to provide energy for separations, most commonly distillation. Although some of this heat can be obtained by exchange with other chemical streams, it is most typically provided either by steam generated directly by the combustion of hydrocarbon fuels (e.g., natural gas/fossil fuels) or by heat transfer from the flue gas from high-temperature furnaces (e.g., from category C1). Most modern chemical processes include a relatively complicated steam system (or other heat transfer fluid system which will generically be referred to herein for simplicity as a steam heat transfer system) to move energy from where it is in excess to where it is needed. This steam system may include multiple pressure levels of steam to provide heat at different temperatures, as well as a steam and condensate recovery system, and is subject to corrosion, fouling, and other operational difficulties, including water treatment and contaminated condensate disposal. The fraction of the energy contained in the steam that can be used to heat process streams is generally limited to 90 to 95% by practical constraints on heat transfer, steam condensation, and boiler water recycle. If the steam was generated by an on-purpose external boiler, at most 80 to 85% of the chemical energy contained in the fuel will be used as heat by the chemical process, since an additional 10 to 15% or more will be lost to flue gas as in first category C1.

The third major category, referred to herein as third category C3, of energy usage in chemical processes is energy utilized to perform mechanical work. This work is primarily utilized for pressurizing and moving fluids from one place to another, and is used to drive rotating equipment such as pumps, compressors, and fans. This third category C3 also includes refrigeration equipment, since it is primarily powered by compression. In most chemical facilities, the energy for this work is provided by steam, obtained either by heat transfer with hot process streams, by heat transfer with partially-cooled flue gas streams from a furnace (e.g., in the convection section) in category C1, or directly from the combustion of hydrocarbons (e.g., natural gas/fossil fuels) in an on-purpose external boiler. Because of limitations on the conversion of thermal energy to mechanical work, the energy efficiency of these uses relative to the contained chemical energy of the hydrocarbons used as fuel is low, typically only 25 to 40%.

It has been unexpectedly discovered that using electricity (e.g., renewable and/or non-renewable electricity) to replace energy obtained from a hydrocarbon fuel in a chemical process can improve the process by increasing overall energy efficiency, while decreasing carbon dioxide emissions. In some cases, using electricity (e.g., renewable and/or non-renewable electricity) to replace energy obtained from a hydrocarbon fuel in a chemical process can also improve reliability and operability, decrease emissions of, for example, NOx, SOx, CO, and/or volatile organic compounds, and/or decrease production costs (e.g., if low-cost electricity is available).

According to embodiments of this disclosure, heat conventionally supplied as thermal energy by the combustion of a fuel (e.g., natural gas/fossil fuels) in a furnace and/or other heating in first category C1 is replaced by electrical heating. Electrical heat, electrical heating, generating heat electrically, electrical heater apparatus, and the like refer to the conversion of electricity into thermal energy available to be applied to a fluid. Such electrical heating includes, without limitation, heating by impedance (e.g., where electricity flows through a conduit carrying the fluid to be heated), heating via ohmic heating, plasma, electric arc, radio frequency (RF), infrared (IR), UV, and/or microwaves, heating by passage over a resistively heated element, heating by radiation from an electrically-heated element, heating by induction (e.g., an oscillating magnetic field), heating by mechanical means (e.g. compression) driven by electricity, heating via heat pump, heating by passing a relatively hot inert gas or another medium over tubes containing a fluid to be heated, wherein the hot inert gas or the another medium is heated electrically, or heating by some combination of these or the like.

According to embodiments of this disclosure, the utilization of steam (or another heat transfer fluid) as in second category C2 is eliminated and/or any steam (or other fluid) utilized solely as an intermediate heat transfer medium is electrically produced or heated (e.g., via electrical heating of water).

According to embodiments of this disclosure, conventional rotating equipment (e.g., steam turbines) utilized in third category C3 is replaced with electrically driven apparatus. According to embodiments of this disclosure, heat removal in third category C3 is replaced by electrically-powered heat removal, e.g., cooling and/or refrigeration. Electrical cooling, electrical coolers, removing heat electrically, electrical cooling or refrigeration apparatus, and the like refer to the removal of thermal energy from a fluid. Such electrical cooling includes, without limitation, cooling by electrically powered apparatus. For example, and without limitation, electrical cooling can be provided by powering a refrigeration cycle with electricity, wherein a refrigerant is compressed by an electrically powered compressor. As another example, electrical cooling can be provided by powering a cooling fan that blows air, wherein the air cools a process fluid or element. In embodiments, electrical heating and cooling can be effected by any electrical source.

FIG. 2 is a schematic of a chemical process powered by renewable energy, according to embodiments of this disclosure. As shown in FIG. 2, a process driven by renewable energy can, in embodiments, appear similar to a conventional chemical process. However, a portion, a majority, or, in some cases, substantially all of the energy input supplied by fuel can be replaced by renewable energy and/or by renewable electricity. Such replacement of fuel input by non-carbon based energy, renewable energy, and/or renewable electricity will allow for a significant decrease in CO₂ emissions, in embodiments. In embodiments, any available form of renewable energy can be employed. However, the gains may be greatest if renewable electricity is utilized. The renewable energy can be obtained from, for example and without limitation, solar power, wind power, or hydroelectric power. Other types of renewable energy can also be applied in chemical plants according to embodiments of this disclosure. For example, in embodiments, concentrated solar power, geothermal energy, and/or the use of direct solar heating can be used to provide thermal energy and to decrease CO₂ emissions.

One of the main advantages to supplying needed energy via (e.g., renewable) electricity can be that the energy efficiency of the process will increase. Table 1 shows the energy efficiency of unit operations exemplifying the three categories of energy use in a chemical plant described above as C1, C2, and C3. It can be seen from Table 1 that the efficiency of each of the three categories of energy consumption is greater when electrical power is used. The gain can be greatest when steam drives for rotating equipment are replaced, according to embodiments of this disclosure, with electrical motors (as in third category C3, discussed hereinabove), which can operate with as much as three times the energy efficiency of steam drives. These gains are only realized when the electricity is derived from non-carbon based renewable sources, since the generation of electricity from carbon-based fuel combustion is only 30 to 45% energy efficient. Energy efficiency gains when using renewable electricity for heating applications (as in first category C1 and second category C2, discussed hereinabove) are smaller, but still significant. The net result is that less total energy will be used if renewable energy is used in place of carbon-based fuels (e.g., natural gas or other hydrocarbons).

TABLE 1 Energy Efficiency of Unit Operations Efficiency from Efficiency from Hydrocarbon Electricity According to Use Combustion This Disclosure C1: Direct Heating up to 80-90% 95+% C2: Heating with Steam up to 80-95% 95+% C3: Rotating Equipment 25-40% 90-95% 

According to this disclosure, non-carbon based energy, renewable energy, and/or electricity (e.g., from renewable and/or non-renewable sources) can be utilized rather than conventional energy sources in categories C1, C2, and/or C3 described hereinabove. In embodiments, electrification is utilized for a majority of or substantially all utilities. In embodiments, electrification is utilized for a majority of or substantially all unit operations. In embodiments, electrification is utilized for a majority of or substantially all utilities and unit operations. In embodiments, electrification is utilized for a majority of or substantially all process applications, engines, cooling and/or heating (e.g., electrically driven heat pumps, refrigeration, electrical heating), radiation, storage systems, or a combination thereof.

In embodiments, the non-carbon based and/or renewable energy source comprises wind, solar, geothermal, hydroelectric, nuclear, tide, wave, ocean thermal gradient power, pressure-retarded osmosis, or a combination thereof. In embodiments, the non-carbon based energy source comprises hydrogen. In embodiments, electricity for electrification as described herein is produced from such a renewable and/or non-carbon based energy source. In embodiments, some or all of the electricity is from a non-renewable and/or carbon-based source, such as, without limitation, combustion of hydrocarbons (e.g., renewable or non-renewable hydrocarbons), coal, or hydrogen derived from hydrocarbons (e.g., renewable or non-renewable hydrocarbons).

The majority of the CO₂ emitted from most chemical plants is a result of fossil fuel combustion to provide energy for the plant. An additional benefit of using renewable energy in chemical synthesis as per embodiments of this disclosure is that the amount of greenhouse gases emitted will be significantly (e.g., by greater than or equal to at least 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, or 100%) reduced relative to an equivalent conventional chemical synthesis plant or method in which hydrocarbons and/or fossil fuel(s) may be combusted. The burning of hydrocarbons (e.g., natural gas, methane) to generate energy results in the production of carbon dioxide (CO₂); this production can be reduced or avoided by the use of renewable energy according to embodiments of this disclosure. In embodiments of this disclosure, the amount of CO₂ produced per ton of product produced is reduced to less than or equal to about 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.75, 0.5, 0.30, 0.25, 0.2, 0.1, 0.05, or 0 tons CO₂ per ton chemical product. Furthermore, in embodiments of this disclosure, the use of renewable energy frees up these hydrocarbons (e.g., natural gas, methane) typically burned for fuel for use as a chemical feedstock (e.g., to make methanol), which is a higher value use.

The use of renewable electricity in the production of chemicals can also lead to operational advantages. For example, in embodiments, electric power can be utilized to provide a more accurate and tunable input of heat, for example to control the temperature profile along a reactor or to change the temperature of specific trays in a distillation column. In embodiments, the use of electric heating in a reaction section (e.g., in a pyrolysis reaction section) leads to better controlled decoking and/or faster decoking. Without limitation, other examples include the use of electric powered refrigeration units to increase the efficiency of separations, and the replacement of inefficient stand-by gas-fired boilers with quick-acting on-demand electrical heaters and steam generators and for other utility uses. The use of electricity may also allow for significant operational advantages during start-up or shut-down, or to respond to process variability. In general, electricity as an energy source can be applied in specific locations and in precise and tunable amounts with a rapid response to process changes, leading to a variety of advantages over the use of thermal/combustion energy.

The use of renewable electricity according to embodiments of this disclosure can also increase the energy efficiency of utilities that supply energy to more than one chemical plant (e.g., an olefin synthesis plant and a nearby ammonia synthesis plant or an olefin synthesis plant and a nearby methanol synthesis plant). For example, if the compressors in an air separation unit that provides oxygen and nitrogen to several different production facilities are powered with renewable electricity, significant energy gains can be achieved relative to supplying this power with steam derived from the combustion of natural gas.

Energy recovery may be provided, in embodiments, via high temperature heat pumps or vapor recompression. The plant may further comprise heat and/or energy storage, for example, for use when an intermittent energy source (IES) is utilized. In embodiments, waste heat can be upgraded to usable temperature levels via electrically driven heat pumps. In other embodiments, energy can be recovered as electricity when process stream pressures are reduced by using a power-generating turbine instead of a control valve. In other embodiments, energy can be recovered as electricity using thermoelectric devices.

The use of renewable electricity to replace natural gas or other hydrocarbons as a source of energy, according to embodiments of this disclosure, can be done as part of a retrofit of an existing chemical process (e.g., an existing methanol, ammonia, or olefin(s) synthesis plant) or as an integral component of the design of a new chemical plant (e.g., a new methanol, ammonia, or olefin(s) synthesis plant). In a retrofit, opportunities for using renewable energy can depend on elements of the existing design, such as the steam system; in a retrofit, careful examination of the entire energy balance and steam system will be required, as electrifying individual pieces of equipment without regard to these considerations may result in energy inefficiencies. In embodiments, as seen in Table 1, the highest efficiency gains are achieved by replacing steam drives for rotating equipment (e.g., in third category C3) with electric motors. However, differing objectives may lead to different choices in partial electrification; in embodiments, in some instances greater CO₂ reductions at the expense of smaller increases in energy efficiency may sometimes be realized by first replacing hydrocarbon-fired furnaces (e.g., in first category C1). In embodiments, if thermal energy and/or steam are obtained from more than one hydrocarbon source, the most advantageous operation can be achieved by eliminating the most expensive and/or polluting fuel sources first. How much renewable energy can be included and to what extent existing fuel consumption and carbon dioxide (CO₂) emissions can be decreased can vary depending on the application, and will be within the skill of those of skill in the art upon reading this disclosure.

In embodiments, planning for the use of renewable energy in the design of a grass-roots chemical facility (e.g., a grass-roots methanol, ammonia, or olefin(s) synthesis plant) can allow for more significant opportunities for better energy efficiency and lower CO₂ emissions. In embodiments, powering all rotating equipment (e.g., in third category C3) with electricity is utilized to realize large gains in energy efficiency. In embodiments, substantially all (or a majority, or greater than 40, 50, 60, 70, 80, or 90%) electric heating (e.g., in first category C1 and/or second category C2) is utilized, and the inefficiencies due to the loss of heat in flue gas are substantially reduced or even avoided. In embodiments, the use of steam generated via the combustion of a fossil fuel (e.g., in second category C2) can be minimized or avoided altogether. In embodiments, a change in catalyst and/or a modification of reactor operating conditions is utilized to allow for less heat generation in a reactor and/or the production of fewer byproducts that are burned. In embodiments, a plant (e.g., a methanol, ammonia, or olefin(s) synthesis plant) design based on the use of renewable electricity allows for enhanced optimization of separations operations, since the relative costs of compression and refrigeration are changed via utilization of renewable electricity as per this disclosure. Such enhanced separations can, in embodiments, also allow for further capture of minor byproducts from vent streams, freeing these minor products up for further use as feedstocks or products. Furthermore, the use of low-cost electricity, according to embodiments of this disclosure, may allow for the introduction of novel technologies such as, without limitation, hybrid gas and electric heaters, variable speed compressor drives, distributed refrigeration, heat pumps, improved distillation columns, passive solar heating of fluids, precise control of reactor temperature profiles, new materials of construction, and quench or cooling using electrically refrigerated diluents. If the cost of electricity is sufficiently low, utilization of such electricity as taught herein may favor the introduction of new electrochemical processes. For new construction, it may be less capital intensive to drive processes electrically, due, for example, to the lack of a (e.g., plant-wide) steam distribution system.

According to embodiments of this disclosure, non-carbon based energy, renewable energy, and/or electricity (renewable, non-renewable, carbon-based, and/or non-carbon based electricity) can be used in the production of nearly every chemical, including but not limited to methanol, ammonia, olefins (e.g., ethylene, propylene), aromatics, and polymers. Non-carbon based energy, renewable energy, and/or electricity can also be used, in embodiments, in the preparation of feedstocks for chemicals and for fuels production, such as in MTBE synthesis, cracking, isomerization, and reforming. In such embodiments, some (e.g., at least about 10, 20, 30, 40, or 50%), a majority (e.g., at least about 50, 60, 70, 80, 90, or 95%), or all (e.g., about 100%) of the heating throughout the plant/process or a section thereof can be provided by electrical heating and/or some (e.g., at least about 10, 20, 30, 40, or 50%), a majority (e.g., at least about 50, 60, 70, 80, 90, or 95%), or all (e.g., about 100%) of the cooling throughout the plant/process or a section thereof can be provided by electrical cooling as described hereinabove.

A generalized chemical synthesis plant operated with an IES according to embodiments of this disclosure will now be described with reference to FIG. 3, which is a schematic of a chemical synthesis plant I utilized to produce at least one chemical product 35, according to embodiments of this disclosure. Without limitation, in specific embodiments, the at least one chemical product comprises a chemical produced, for example, as described in U.S. Provisional Patent Application Nos. 62/792,631, 62/792,632, 62/792,633, 62/792,634, and 62/792,635, entitled Use of Renewable Energy in the Production of Chemicals, or U.S. Provisional Patent Application Nos. 62/792,636 and 62/792,637, entitled Use of Intermittent Energy in the Production of Chemicals, which are being filed on Jan. 15, 2019, the disclosure of each of which is hereby incorporated herein for purposes not contrary to this disclosure. Without limitation, in specific embodiments, the at least one chemical product comprises ethylene produced, for example, by cracking in one or more cracking reactors (e.g., via an olefin synthesis) as described in U.S. Provisional Patent Application Nos. 62/792,612 and 62/792,615, entitled Use of Renewable Energy in Olefin Synthesis, which are being filed on Jan. 15, 2019, the disclosure of each of which is hereby incorporated herein for purposes not contrary to this disclosure); ammonia produced, for example, in one or more ammonia synthesis reactors (e.g., via an ammonia synthesis as described in U.S. Provisional Patent Application Nos. 62/792,617 and 62/792,619, entitled Use of Renewable Energy in Ammonia Synthesis, which are being filed on Jan. 15, 2019, the disclosure of each of which is hereby incorporated herein for purposes not contrary to this disclosure); methanol produced, for example, in one or more methanol synthesis reactors (e.g., via a methanol synthesis as described in U.S. Provisional Patent Application Nos. 62/792,622 and 62/792,627, entitled Use of Renewable Energy in Methanol Synthesis, which are being filed on Jan. 15, 2019, the disclosure of each of which is hereby incorporated herein for purposes not contrary to this disclosure); propylene produced, for example, by cracking; ethylene oxide produced, for example, by oxidation of ethylene; monoethylene glycol produced, for example, by hydration of ethylene oxide; ethylene dichloride produced, for example, by chlorination of ethylene; vinyl chloride produced, for example, from ethylene dichloride; alpha-olefins produced, for example, by oligomerization; olefins produced, for example, by dehydrogenation of paraffins; isoparaffins produced, for example, by the isomerization of normal paraffins (e.g., isobutane produced from n-butane); aromatics (BTX) produced, for example, from paraffins and/or naphthenes by cyclization and/or dehydrogenation; aromatics produced, for example, from naphtha by cyclization and/or dehydrogenation; ethylbenzene produced, for example, by alkylation of benzene with ethylene; styrene produced, for example, by dehydrogenation of ethyl benzene; cumene produced, for example, by alkylation of benzene with propylene; phenol produced, for example, by oxidation of cumene; terephthalic acid produced, for example, by the oxidation of paraxylene; oxygen produced, for example, by separation from air; nitrogen produced, for example, by separation from air; MTBE produced, for example, by etherification of isobutylene; polyethylene, polypropylene, polyvinylchloride, polystyrene, polycarbonate, and/or polyethylene terephthalate (PE, PP, PVC, PS, PC, PET) produced, for example, by polymerization. Without limitation, in other specific embodiments, the at least one chemical product comprises acetic acid produced, for example, by methanol carbonylation; vinyl acetate produced, for example, by the reaction of acetic acid with ethylene; propylene produced, for example, by methanol oligomerization (generally known as the methanol-to-olefins process); acrylic acid produced, for example, by oxidation of propylene; methacrolein produced, for example, by oxidation of isobutylene; methyl methacrylate produced, for example, by oxidation of methacrolein; acrylonitrile produced, for example, by ammoxidation of propylene; sulfuric acid produced, for example, by the oxidation of sulfur; nitric acid produced, for example, by the oxidation of ammonia; propylene glycol produced, for example, by the hydration of propylene; one or more nylon precursors selected from adipic acid, caprolactam, cyclohexanone, 1,6 diaminohexane, or a combination thereof; or polyvinyl alcohol (PVA), polyacrylates, polymethylmethacrylate (PMMA), nylons.

This disclosure describes a chemical synthesis plant for producing a chemical product, wherein the chemical synthesis plant is configured/operable such that a majority of the net energy required by one or more sections, units, or groups of like units or unit operations of the chemical synthesis plant is provided by intermittent energy source (e.g., intermittent energy comprising non-carbon based energy (E_(NC)) from a non-carbon based energy source (e.g., not produced via the combustion of a carbon-based fuel such as a hydrocarbon), renewable energy (e.g., from non-fossil fuel derived energy (E_(NF))), or from electricity, and/or from renewable electricity)). The E_(NC) or E_(NF) source may, in embodiments, comprise, primarily comprise, consist essentially of, or consist of electricity. The E_(NC) or E_(NF) source may, in embodiments, comprise, primarily comprise, consist essentially of, or consist of renewable electricity. In embodiments a portion (e.g., greater than or equal to about 5, 10, 20, 30, 40, 50), a majority (e.g., greater than or equal to about 50, 60, 70, 80, 90, or 95%), or all (e.g., about 100%) of the net energy needed by the overall chemical synthesis plant, a section of the plant (e.g., a feed pretreating section, a reaction section, and/or a product purification section), a group of like units (e.g., compressors, power providing units, heating units, reboilers, cooling units, refrigeration units, separators, reactors, distillation/fractionation columns), or unit operations (e.g., compression, powering, heating operations, cooling operations, reactions, separations) of the plant, or a combination thereof is provided by electricity, renewable energy (e.g., from non-fossil fuel derived energy (E_(NF))), and/or non-carbon based energy (E_(NC)). In embodiments, electricity is provided from a renewable intermittent energy source, such as, without limitation, wind (e.g., via wind turbines) or solar (e.g., solar via photovoltaic (PV) panels). In embodiments a portion (e.g., greater than or equal to about 5, 10, 20, 30, 40, 50), a majority (e.g., greater than or equal to about 50, 60, 70, 80, 90, or 95%), or all (e.g., about 100%) of the electricity, renewable energy (e.g., from non-fossil fuel derived energy (E_(NF))), and/or non-carbon based energy (E_(NC)) needed by the overall chemical synthesis plant, a section of the plant (e.g., a feed pretreating section, a reaction section, and/or a product purification section), a unit or a group of like units (e.g., compressors, power providing units, heating units, reboilers, cooling units, refrigeration units, reactors, separators, distillation/fractionation columns) or unit operations (e.g., compressing, powering, separating, heating, cooling, reacting) of the chemical synthesis plant, or a combination thereof, and conventionally provided in a similar chemical synthesis plant via combustion of a fuel, a carbon-based fuel, and/or a fossil fuel and/or the use of steam (e.g., that was itself generated via the combustion of such a fuel) as an intermediate heat (and/or energy) transfer fluid, is provided without combusting a fuel, a carbon-based fuel, and/or a fossil fuel and/or without the use of steam generated by the combustion of such a fuel as an intermediate heat (and/or energy) transfer fluid. In embodiments, the net energy for the overall plant or one or more sections, units or groups of like units of the plant is provided by electricity from a renewable intermittent energy source. In embodiments, the energy is provided by electricity from an intermittent renewable energy source, when the renewable IES is available (e.g., online or stored) or below a threshold price. For example, in embodiments, heating is electrically provided via resistive heating, wherein the electricity is obtained primarily from an IES, when available or below a threshold price. Available intermittent energy can include ‘online’ energy provided directly via the IES (e.g., via solar cells) and stored energy obtained from the IES while online and later utilized within the plant.

In embodiments, a chemical synthesis plant of this disclosure is configured such that a majority (e.g., greater than 50, 60, 70, 80, or 90%) of the net energy needed for powering, heating, cooling, compressing, separating, or a combination thereof utilized via the feed pretreating system, one or more reactors, a product purification system, or a combination thereof is provided by electricity. In embodiments, the electricity is provided from an IES, when the IES is available or below a threshold price.

In embodiments, a chemical synthesis plant according to embodiments of this disclosure is a large plant having a production capacity for the desired chemical product of greater than or equal to about 10,000 tons per year, 100,000 tons per year, 250,000 tons per year, 500,000 tons per year, or 10,000,000 tons per year. At the sizes anticipated in this disclosure, the amount of energy provided by the IES will be correspondingly large. In embodiments, a partially or completely electrified plant according to the methods of this disclosure will consume at least (i.e., greater than or equal to) about 10, 15, 20, 25, 50, 100, 150, 200, 300, 400, 500, 750, or 1000 MW of electricity from the IES.

Although a specific embodiment of a chemical synthesis plant will be utilized to describe the electrification of a chemical synthesis plant with an IES, as disclosed herein, it is to be understood that numerous arrangements of units and a variety of chemical synthesis technologies can be electrified as per this disclosure, as will be obvious to those of skill in the art upon reading the description herein.

With reference to FIG. 3, which is an overview of a generalized chemical synthesis plant I, a chemical synthesis plant may be considered to include one or more of the following process sections for converting a feed stream 5 comprising one or more reactants into a chemical product stream 35 (and optionally one or more byproduct streams 31): a feed pretreating section 10, a reaction (or primary reaction) section 20, a product purification section 30, or a combination thereof. Other sections, such as a recycling section, an energy (e.g., electricity) production and/or energy storage (e.g., hydrogen storage) section are also within the scope of this disclosure. Such sections will be described briefly in the next few paragraphs, and in more detail hereinbelow.

As indicated in the chemical synthesis diagram of FIG. 3, a feed pretreating section 10 of a chemical synthesis plant is operable to prepare (e.g., remove undesirable components (e.g., sulfur) from, adjust temperature and/or pressure of a feed) a reactant feed 5 for reaction, providing a pretreated feed 15. In applications, a chemical synthesis plant of this disclosure does not comprise a feed pretreating section. A reaction or “chemical synthesis” section 20 is operable to produce a desired chemical product from the pretreated feed 15 and thus provide a crude chemical product stream 25. A product purification section 30 is operable to separate a purified chemical product 35 from the crude chemical product stream 25. In applications, a chemical synthesis plant of this disclosure does not comprise a product purification section.

As depicted in FIG. 3 and mentioned above, energy (E) input to or within the chemical synthesis plant or one or more sections or groups of units, like units, or unit operations thereof (that may conventionally be provided via a carbon based energy (E_(C)) 2A from a carbon based energy source, a fossil fuel derived energy (E_(F)) 3A from a fossil fuel-based energy source, or via the use of steam (e.g., steam generated for this purpose using energy derived from a carbon or fossil fuel based energy source) solely or primarily as a heat or energy transfer medium (S_(HT)) 1), may be partially or completely replaced by non-carbon based energy (E_(NC)) 2B from a non-carbon based energy source, renewable/non-fossil fuel based energy (E_(NF)) 3B from a renewable intermittent energy source, and/or electricity (e.g., intermittent electricity and/or renewable intermittent electricity). The carbon based energy (E_(C)) 2A, the fossil fuel derived energy (E_(F)) 3A, or both can be partially or completely replaced by electricity. The electricity may be derived from a non-carbon based fuel, a renewable fuel, a renewable energy source, or a combination thereof, in embodiments. A benefit derived via the herein disclosed system and method may be a reduction in the greenhouse gas (GHG) emissions 4 from the chemical synthesis plant or process. The above-noted elimination or reduction of the steam system may also result in lower capital and operating costs, in embodiments.

As mentioned above and depicted in FIG. 3, energy (E) input to or within the chemical synthesis plant or one or more sections or groups of units, like units, or unit operations thereof (that may conventionally be provided via a carbon based energy (E_(C)) source, a non-renewable energy source, a non-electrical energy source, or via the use of steam solely or primarily as a heat or energy transfer medium (S_(HT)) and/or generated by the combustion of a non-renewable fuel), may be partially or completely replaced by energy from a non-carbon based energy (E_(NC)) source, a renewable energy source, such as intermittent renewable electricity, electricity (from any source), or without the use of steam solely or primarily as a heat or energy transfer medium (S_(HT)) and/or generated by the combustion of a fuel. A benefit derived via the herein disclosed system and method may be a reduction in the greenhouse gas (GHG) emissions 4 from the chemical synthesis plant or process.

Although not intending to be limited by the examples provided herein, a description of some of the ways a chemical synthesis plant can be electrified with an IES according to embodiments of this disclosure will now be provided with reference to the exemplary chemical synthesis plant I of FIG. 3. The steps, sections, groups of units or unit operations described may be present or operated in any suitable order, one or more of the steps, sections, units, or unit operations may be absent, duplicated, replaced by a different step, section, unit or unit operation, and additional steps, sections, units or unit operations not described herein may be employed, in various embodiments. Additionally, although a step is noted as being in a particular section, the step could also be considered a part of another section.

As noted hereinabove, in embodiments, a chemical synthesis plant of this disclosure comprises a feed pretreating section 10. Such a feed pretreating section 10 can be operable to remove one or more components such as, without limitation, catalyst poisons, from a feed (or multiple feeds), adjust a pressure of the feed or feeds to a desired operating pressure within a downstream (e.g., reaction) section 20, adjust the temperature of the feed or feeds to a desired operating temperature, and/or otherwise alter a feed or feeds prior to a downstream (e.g., reaction) section 20.

As noted hereinabove, in embodiments, a chemical synthesis plant of this disclosure comprises a chemical synthesis section 20. Such a chemical synthesis section 20 can be operable to produce a desired chemical (or more than one desired chemical) from the feed 5 or the pretreated feed(s) 15. Producing the desired chemical can comprise maintaining one or more reactors at a desired temperature(s)/temperature profile(s) and/or pressure(s), providing additional components (e.g., diluents, catalyst) at a desired composition, temperature and/or pressure, to the one or more reactors, extracting the chemical product from the one or more reactors, and the like, to provide the crude chemical product 25. The one or more reactors can be configured to operate in series or in parallel, and one or more chemical reaction may occur, either in series or in parallel. The reactions occurring may be endothermic, exothermic, or thermoneutral in nature, and the net of all reactions occurring may be endothermic, exothermic, or thermoneutral in nature.

As noted hereinabove, in embodiments, a chemical synthesis plant of this disclosure optionally comprises a product purification section 30. Such a product purification section 30 can be operable to separate a chemical product or multiple products and byproducts from the crude chemical product in any number of ways. For example, separations may be effected via one or more distillation columns and associated reboilers, flash separators, solvent extractors, extractive distillation units, crystallizers, evaporators, phase separators (e.g., decanters, cyclones, etc.), absorbers, adsorbers, membranes, and the like, to provide the chemical product stream 35.

As indicated in FIG. 3, in embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net energy needed within the chemical synthesis plant or one or more sections thereof (e.g., the energy E1 needed within the feed pretreating section 10, the energy E2 needed within the reaction section 20, and/or the energy E3 needed within the product purification section 30) [or within one or more units or groups of units (e.g., compressors, separators, distillation columns) or unit operations (e.g., compression, powering, separating, heating, cooling), as discussed hereinbelow] is provided from a non-carbon based energy source, from a renewable energy source, such as renewable electricity, or from electricity (from any source, renewable and/or non-renewable). In embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net energy (e.g., E=E1+E2+E3) needed within the chemical synthesis plant or one or more sections thereof (e.g., the energy E1 needed within the feed pretreating section 10, the energy E2 needed within the reaction section 20, and/or the energy E3 needed within the product purification section 30) [or within or one or more units or groups of units (e.g., compressors, separators, distillation columns) or unit operations (e.g., compression, powering, separating, heating, cooling), as discussed hereinbelow] is provided without burning a fuel and/or without producing steam solely or at all as a heat (and/or energy) transfer medium.

In embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net energy needed by one or more units or groups of units or unit operations is provided from a non-carbon based energy source, from a renewable energy source, such as renewable electricity, and/or from electricity (from any source, renewable and/or non-renewable). For example, without limitation, in embodiments, such units comprise compressors (e.g., feed compressors and/or refrigeration compressors), pumps, separators (e.g., distillation columns, absorption units and/or strippers), extractors (e.g., for liquid-liquid extraction and/or extractive distillation), reactors for a particular reaction (e.g., individual reactors or multiple reactors in series and/or in parallel), heaters (e.g., heat exchangers and/or reboilers), coolers (e.g., refrigeration units and/or cryogenic units, blowers, cooling water systems), equipment for regeneration (e.g., for the regeneration of catalysts, adsorbers, or stripping solutions), or combinations thereof.

In embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net energy needed for a set of operations (e.g., compression, pumping, powering, mixing, separating, heating, cooling, reacting, recycling, energy storing and/or energy producing) is provided from a non-carbon based energy source, from a renewable energy source, such as renewable electricity, of from electricity (from any source, renewable and/or non-renewable).

A significant fraction of the energy (E) used in chemical plants is used for heating and cooling (Q); because of its importance, the fraction of all net energy transferred as heating and cooling can be considered separately. As noted above, in embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net energy needed for heating and/or cooling is provided from a non-carbon based energy source, from a renewable energy source, such as renewable electricity, and/or from electricity (from any source, renewable and/or non-renewable). For example, in embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net heat input or removal needed within the chemical synthesis plant or one or more sections thereof (e.g., the heat input or removal Q1 needed within the feed pretreating section 10, the heat input or removal Q2 needed within the reaction section 20, and/or the heat input or removal Q3 needed within the product purification section 30) and provided by one or more units or groups of units (e.g., refrigeration units, heat exchangers) is provided from a non-carbon based energy source, from a renewable energy source, such as renewable electricity, and/or from electricity (from any source, renewable and/or non-renewable). According to this disclosure, when cooling process streams, as much heat as possible should be used to heat other process streams. However, below a certain temperature, further heat transfer is no longer effective or useful, and blowers, cooling water, and/or refrigeration (which require an energy input for heat removal) are utilized. In embodiments, for example, heat exchangers, refrigeration units, or a combination thereof for altering the temperature of process streams may be powered electrically. In embodiments, refrigeration units contain one or more electrically-powered compressors. In embodiments, steam is not utilized solely as an intermediate heat and/or energy transfer stream, and the plant or section(s) thereof do not comprise an elaborate steam system as is conventionally employed for energy transfer. In embodiments, steam is used as a heat transfer fluid and is not used to do mechanical work, for example to drive a pump or compressor. In embodiments, heating is provided via resistive heating. In embodiments, heating is provided via inductive heating. In embodiments, heating is provided electrically to radiative panels that then transfer heat to the process by radiation.

Reactors of the reaction section 20 or elsewhere which may, in embodiments, conventionally be heated via the burning of a fuel may, according to embodiments of this disclosure, be heated without burning a fuel (and, thus, without the concomitant production of corresponding flue gas). For example, reactor(s) can, in embodiments, be electrically heated. In this manner, greenhouse gas emissions from a plant can be reduced and, in some instances, hydrocarbons conventionally burned as a fuel within the reaction section 20 (or elsewhere) can be utilized in the production of additional chemical product either within that plant or in a different chemical production plant. In embodiments, energy efficiency is increased by the elimination of the flue gas, since the loss of heat contained in the flue gas to the atmosphere is eliminated. Utilization of electrical heating of reactors can, in embodiments, provide for an enhanced temperature profile along a reaction zone or reactor. For example, a desired heat flux may be provided along a length of a reactor, providing enhanced temperature control for reaction, shifting equilibrium, and/or minimizing coking and/or catalyst deactivation.

In embodiments, one or more reactors, a feed preparation system, a product purification system, or a combination thereof produces a lights stream (e.g., a flue gas, purge gas, or tailgas), wherein the lights stream, the reactants utilized in the one or more reactors, or a combination thereof comprise a component selected from hydrogen, carbon monoxide, one or more light hydrocarbon (e.g., a C₁ hydrocarbon, C₂ hydrocarbon, C₃ hydrocarbon, and/or a C₄ hydrocarbon), or a combination thereof, and a chemical synthesis plant of this disclosure is not configured for combustion of the lights stream, the component, or both as a fuel. In embodiments, the energy of such combustion is replaced by electricity.

In embodiments, electricity can be utilized to produce colder cooling water (e.g., 2, 5, 10 or 15° C. colder) than conventional, enhancing downstream operations. In embodiments, electrical power can be used in operations to improve the quality of water to be used for cooling water, e.g., by removing contaminants. In embodiments, electricity can be used to heat gas or liquid streams used to regenerate a catalyst, adsorbent, or absorption solution, for example steam stripping of an adsorbent to regenerate it. In embodiments, electricity is used to regenerate an amine absorption solution. In embodiments, electricity can be used to preheat gases used in reactions. In embodiments, electricity can be used to vaporize feeds and/or diluents, for example, without limitation, steam or naphtha. In embodiments, electricity can be used to heat trace lines or vessels and keep gases and/or liquids at a desired temperature during storage and/or transfer when they would otherwise cool off. In embodiments, electricity can be used to power a thermoelectric device and/or a heat pump to enable simultaneous heating and cooling. In embodiments, electricity can be used to provide “trim heating,” wherein a gas or liquid stream, previously heated by heat transfer from a hot reaction product stream (via a feed/product interchanger), is further heated prior to feeding said stream to a reactor or other downstream apparatus. In embodiments, electricity can be used to provide “start-up” heating to a process, wherein an electrically powered heater may be used to preheat a reactant or other process stream when a plant is started-up but is no longer utilized when the plant is on line, as other heat sources, such as without limitation hot reactor product streams, become available.

As noted above, in embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net energy needed for compression within the chemical synthesis plant or one or more sections thereof (e.g., the feed pretreating section 10, the reaction section 20, and/or the product purification section 30) is provided from a non-carbon based energy source, from a renewable energy source, such as renewable electricity, and/or from electricity (from any source, renewable and/or non-renewable). Such compression may be utilized, for example, to raise the pressure of the feed 5 in pretreating section 10, to raise the pressure of a stream within the reaction section 20, to raise the pressure of a stream within the product purification section 30, and/or to raise the pressure of a recycle stream.

For example, according to embodiments of this disclosure, compression may be effected via electric motor-driven compressors, rather than via turbines driven by the combustion of a gas/fuel or via turbines powered by steam produced from the combustion of hydrocarbons. In embodiments, compressors are operated with turbines driven by steam produced with electric heating. For example, an electric motor and/or a turbine driven by steam produced electrically may be utilized to provide compression throughout the chemical synthesis plant or one or more sections thereof, or for one or more operations (e.g., refrigeration). In embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the compressors within one or more sections of the chemical plant or a group of like units (e.g., refrigeration units) or operations (e.g., stream pressurizing, cooling, refrigerating) utilize an electric motor-driven compressor and/or a turbine driven by electrically produced steam.

In embodiments, high pressure streams within the plant are utilized to produce electricity for use within one or more sections of the chemical synthesis plant. For example, pressure let down steps within the chemical synthesis plant or one or more sections thereof may be effected via turbine(s) rather than control valves, in embodiments.

In embodiments, steam generated by the combustion of fuels or produced solely for heat and/or energy transfer is not utilized in a chemical synthesis plant and method of this disclosure (e.g., in the pretreating section 10, the reaction section 20, and/or the product purification section 30). In this manner, a chemical synthesis plant according to this disclosure can be operated, in embodiments, without an elaborate steam heat and/or energy transfer system (which may be conventionally utilized in a chemical plant for producing the same chemical). In some applications, for example where steam is utilized within a reactor as a feed component and/or diluent, such steam may be produced via heat transfer with a process stream within the chemical synthesis plant and/or may be produced electrically. In embodiments, steam generated via heat transfer with a process stream may be superheated using electricity. In embodiments, the electrical superheating of low temperature steam allows for improved heat and energy recovery. In embodiments, steam is not utilized throughout the chemical synthesis plant as a commodity or utility. In embodiments, a chemical synthesis plant of this disclosure is essentially steam-free, or utilizes substantially less steam (e.g., uses at least 10, 20, 30, 40, 50, 60, 70, 80, 90, or 100 volume percent (vol %) less steam) than a conventional plant for producing the same chemical. For example, a conventional plant for producing the same chemical may utilize steam production for reboilers of distillation columns of the feed pretreating section 10 and/or the product purification section 30, may utilize steam production to drive steam turbines for compressing process and/or recycle streams, or may utilize steam production to drive steam turbines for refrigeration. In embodiments, steam is not produced for these operations in a chemical plant according to this disclosure, or substantially less steam is produced (e.g., at least 10, 20, 30, 40, 50, 60, 70, 80, 90, or 100 volume percent (vol %) less steam). In embodiments, steam is used as a heat transfer fluid, but is not used to do mechanical work (e.g., to drive a compressor or pump.) In embodiments, the steam generated for these operations is primarily (e.g., of the total steam utilized, the greatest percentage is electrically produced), mainly (e.g., greater than 50% of the steam is electrically produced) or substantially all electrically produced. In embodiments, the steam utilized as a reactant or diluent is primarily (e.g., of the total steam utilized, the greatest percentage is electrically produced), mainly (e.g., greater than 50% of the steam is electrically produced) or substantially all electrically produced. In embodiments, the steam utilized as a reactant and/or diluent is generated using resistive heating. In embodiments, the steam utilized as a reactant and/or a diluent is generated using an electrode boiler or an electric immersion heater. In embodiments, steam is superheated using electricity.

In embodiments, in a chemical synthesis plant or process of this disclosure, more energy is utilized directly ‘as-is’, for example, utilizing heat from a hot product effluent stream to heat a feed stream, rather than being transformed, e.g., via the generation of steam and the conversion of the thermal energy to mechanical energy via a steam turbine. According to embodiments of this disclosure, the use of energy directly can increase the energy efficiency of the chemical synthesis plant, for example by reducing energy efficiency losses that occur when heat is converted to mechanical energy and/or via flue gas.

In embodiments, electricity can be used to provide the motive force for fluids. For example, electricity can be used to power pumps to move and/or pressurize liquids, and/or to power air blowers and/or fans. In embodiments, a fraction, a majority, or all (e.g., 20, 30, 40, 50, 60, 70, 80, 90, or 100%) of the number of pumps utilized in the chemical synthesis plant are electrified.

As noted above, in embodiments, a majority, greater than 20, 30, 40, 50, 60, 70, 80, or 90%, or substantially all of the net energy needed for separating/separations is provided from a non-carbon based energy source, from a renewable energy source, such as renewable electricity, of from electricity (from any source, renewable and/or non-renewable). A variety of separations can be effected electrically, as per embodiments of this disclosure. Separations based on temperature and/or pressure change can include heating/cooling and/or compressing electrically, as described above. For example, distillations, gas/solid separations, absorption, stripping, solvent extraction, extractive distillation, pressure swing adsorption, temperature swing adsorption, flash separation, crystallization or a combination thereof may be electrified in embodiments of this disclosure. By way of non-limiting example, distillation columns of one or more sections of the plant can be electrically heated, in embodiments. In embodiments, reboilers associated with a distillation column are electrically heated and/or are heated via steam (or another fluid) produced electrically. In embodiments, reboilers associated with a distillation column are heated with an electric immersion heater. In embodiments, electricity is used to power a thermoelectric device or a heat pump to provide both heating (to the reboiler) and cooling (to the condenser) in a distillation column. In embodiments, steam for use in stripping is generated electrically.

As noted above, when utilizing electricity from a renewable source that has a potentially or known intermittent supply (e.g., an intermittent energy source or IES), various steps can be taken to maintain operation of the chemical synthesis plant, according to embodiments of this disclosure.

With reference to FIG. 4, which is a schematic of a chemical synthesis plant II according to embodiments of this disclosure, a net energy E_(NET) needed throughout chemical synthesis plant II of this disclosure (e.g., for powering 101, pumping 102, heating 103, cooling 104, compressing 105, and/or separating 106, and the like) can be provided by intermittent energy E_(I) (e.g., electricity from a renewable IES) when the intermittent energy source (e.g., the sun) is available and can be provided from stored intermittent energy (E_(SI)) and/or a non-intermittent energy source E_(NI) (e.g., electricity from a non-intermittent source, which may be online or stored) when the intermittent energy source is not available.

As depicted in the embodiment of FIG. 4, a variety of energy storage apparatus 50 can be utilized to store energy, for example a portion of the available intermittent energy E_(I), for utilization when the E_(I), is not available. By utilizing the chemical synthesis plant and method of this disclosure, substantially continuous operation of the chemical synthesis can be provided, while utilizing primarily energy from an IES, which can be a renewable IES.

A variety of energy storage systems and methods for utilization in a chemical synthesis plant II operated with an IES as per this disclosure will now be described with reference to FIGS. 5A-5D.

In embodiments, compression can be utilized to store energy for intermittency of electric supply. FIG. 5A is a schematic of a system IIIA for storing energy via compression, according to embodiments of this disclosure. In embodiments, a for-storage stream 40A comprising a gaseous feed(s) is compressed in a compressor C1 and the resulting compressed stream 41A is stored in a storage vessel 50A for intermittency of energy (e.g., electrical energy) supply. The for-storage stream 40A can comprise one or more feed streams, one or more chemical products, or one or more intermediates produced by the chemical synthesis process. At least a portion 42A of the stored, compressed material can be returned to the chemical synthesis process as a process stream subsequent storage (e.g., when intermittent electricity to run a compressor utilized to provide the compressed material is not available). In embodiments, the gaseous feeds are compressed in compressor(s) C1 and stored in storage vessel 50A at a pressure greater than a process operating pressure. For example, the gaseous feed(s) can be compressed to and/or stored at a ‘high’ pressure of greater than or equal to about 1 MPa, 10 MPa, or 100 MPa in embodiments. In embodiments, when the pressure of the stored, compressed stream is reduced, electricity can be generated and/or mechanical work can be performed.

In embodiments, gaseous feeds are compressed and liquefied when intermittent electricity is readily available and/or economical, and vaporized and expanded to generate electricity and/or to provide a feed somewhere within chemical synthesis plant I when intermittent electricity is not readily available and/or is not economical. For example, as depicted in the embodiment of FIG. 5A, an energy storage system IIIA can comprise an expander 45 operable to expand at least a portion 43A of the compressed, stored stream to provide work W. Expander 45 can, in embodiments, be a turboexpander. The work can be utilized, in embodiments, to produce energy for use elsewhere throughout the system. For example, expander 45 may be used to drive a compressor or generator 46, and thus provide compression or electricity, respectively. Following expansion in expander 45, the pressure-reduced stream 43N can be returned to the chemical synthesis process (for example, via stream 42′), for example, as a feed stream therein and/or sent for storage or sale or can be recompressed in compressor C1 and stored in storage vessel 50A when IES is again available.

In embodiments, a for-storage stream comprising oxygen or nitrogen generated in an air separation plant (e.g., an electrically driven ASU which can be operable to provide oxygen or nitrogen to the chemical synthesis) is stored under pressure (e.g., in a storage vessel 50A) for later use, possibly with electricity generation via expansion in an expander 45. In embodiments, the for-storage stream 40A comprises hydrogen. In embodiments, the for-storage stream 40A comprises methane. In embodiments, the for-storage stream 40A comprises ethane. In embodiments, the for-storage stream 40A comprises propane.

Alternatively or additionally, one or more chilled fluids or cryogenic liquids can be stored for intermittency of electric supply. FIG. 5B is a schematic of a system IIIB for storing energy via cooling, according to embodiments of this disclosure. In embodiments, a for-storage stream 40B comprising a fluid utilized or produced within the chemical synthesis plant (e.g., one or more feed streams, one or more chemical products, one or more intermediates produced by the chemical synthesis process, or a refrigerant already in use) is cooled in cooling or refrigeration apparatus 60 and the resulting cooled stream 41B is stored in a storage vessel 50B for intermittency of energy (e.g., electrical energy) supply. In embodiments, feeds, intermediates, or products/byproducts are chilled and stored for use as a refrigerant for intermittency of electric supply. In embodiments, nitrogen is chilled and stored for use as a refrigerant for intermittency of electric supply. At least a portion 42B of the stored, cooled material can be returned to the chemical synthesis process as a process stream subsequent storage (e.g., when intermittent electricity to run a cooling apparatus utilized to provide the cooled material is not available). In embodiments, at least a portion 43B of the cooled stored stream and a process stream 71 of the chemical synthesis plant can be introduced into a heat exchanger 70, whereby heat exchange between the process stream 71 and the at least a portion of the stored, cooled material 43B produces a cooled process stream 71A and a heated stream 43B′ comprising the now warmer material (e.g., gas or liquid). Via this storage system and method, a material produced in the chemical synthesis process (e.g., propane or ammonia) can, in embodiments, be chilled (e.g., via introduction into cooling apparatus 60 via for-storage stream 40B) when intermittent electricity is readily available and used in heat exchanger 70 to cool streams (e.g., process stream 71) throughout the chemical synthesis plant when electricity is not available; the resulting warmer liquid or gas (e.g., in heated stream 43B′) can then be utilized as a feed and/or withdrawn as a product. In embodiments, as the stored, cooled material is warmed the pressure is increased and gas is expanded through an expander to provide work. The expander can, in embodiments, be a turboexpander. The work can be utilized, in embodiments, to produce energy for use elsewhere throughout the system. For example, the expander may be used to drive a compressor or generator, and thus provide compression or electricity, respectively. Following expansion, the pressure-reduced stream can be returned to the chemical synthesis process, for example, as a feed stream therein and/or sent for storage or sale or can be recompressed and stored when IES is again available. That is, in embodiments, both pressure energy and refrigeration are stored; as warming the refrigerant provides pressure, this pressure can also be utilized to provide energy throughout the plant.

Alternatively or additionally, hydrogen (e.g., compressed hydrogen) is stored and/or passed through a fuel cell for intermittency of electric supply. In embodiments, a for-storage stream comprising hydrogen is stored and later passed through a fuel cell to generate electricity to handle intermittency of electric supply. FIG. 5C is a schematic of a system IIIC for storing energy via hydrogen, according to embodiments of this disclosure. In embodiments, a for-storage stream 40C comprising hydrogen is stored in a storage vessel 50C for intermittency of energy (e.g., electrical energy) supply. In embodiments, system IIIC comprises a compressor C1, and the for-storage hydrogen in for-storage stream 40C is compressed in compressor C1 and the compressed hydrogen in compressed hydrogen stream 41C stored in storage vessel 50C. In embodiments, the for-storage stream 40C comprising hydrogen, the compressed for-storage stream 41C, and/or a stored stream of hydrogen 43C (which may comprise compressed or non-compressed hydrogen, in embodiments) can be introduced into a fuel cell 80 of system IIIC. Fuel cell 80 can comprise any fuel cell (or flow battery) operable to produce electricity from hydrogen. For example, fuel cell 80 can comprise a proton-exchange membrane (PEM) fuel cell (PEMFC) (also known as a polymer electrolyte membrane fuel cell), a solid oxide fuel cell (SOFC), or the like. Fuel cell 80 is operable to produce electricity, indicated at 84, (and water, indicated at 83) via introduction of hydrogen; and air thereto via for-storage stream 40C and/or stored hydrogen stream 43C; and 81, respectively. Emissions may be removed at 82. Heat that is produced, indicated at 85, can be ‘waste’ heat or can, in embodiments, be utilized elsewhere in the chemical synthesis plant (e.g., for cogeneration or process heating).

Alternatively or additionally, hydrogen (e.g., compressed hydrogen) is stored and/or combusted for intermittency of electric supply. In embodiments, a for-storage stream comprising hydrogen is stored, and later combusted to produce steam and heat. In embodiments, the hot steam is used as a reactant or process diluent. In embodiments, the temperature of the hot steam is higher than that of the process stream to which it is added so that the temperature of the process stream is increased. In embodiments, the combustion is used to generate electricity (e.g., in a turbine.)

Alternatively or additionally, heat can be stored for intermittency of electric supply. In embodiments, heat (e.g., as a heated or superheated fluid) is stored for heating one or more process streams when electrical heating is not available. FIG. 5D is a schematic of a system IIID for storing energy via heating, according to embodiments of this disclosure. In embodiments, a for-storage stream 40D comprising a process stream (e.g., one or more feed streams, one or more chemical products, or one or more intermediates produced by the chemical synthesis process) is heated in a heating apparatus 90 (which can be, in embodiments, an electrically heated apparatus) and stored in a storage vessel 50D for intermittency of energy (e.g., electrical energy) supply. Heating apparatus 90 is configured to heat the for-storage stream introduced thereto via for-storage stream 40D. Heating apparatus 90 can be any heating apparatus known to those of skill in the art. In embodiments, heating apparatus 90 comprise an electrically heated heating apparatus. Heated stream 41D is introduced into storage vessel 50D, for storage. The stored, heated stream can be introduced into a heat exchange apparatus 91 for transferring heat from the stored, heated stream 43D to a process stream 71 of the chemical synthesis process. A heated process stream 71A and a cooled heat exchanger fluid 43D comprising the stored, heated stream subsequent heat exchange therefrom can be removed from heat exchange apparatus 91. Heat exchange apparatus can be any heat exchange apparatus known to those of skill in the art. The heated process stream 71B, the cooled heat exchange stream in cooled heat exchanger fluid 43D, or both can be returned to the chemical synthesis process, in embodiments.

Alternatively or additionally, thermal energy can be stored by heating a solid or liquid heat storage material, in embodiments. This material can be heated by a process stream or directly by a dedicated heating apparatus. In embodiments, the dedicated heating apparatus is powered by electricity. At a later time, heat can be recovered by heat exchange with a process stream that is to be heated. In embodiments, the solid or liquid heat storage material is a molten salt.

Alternatively or additionally, thermal energy can be stored using one or more phase change materials wherein thermal energy is captured (e.g., from a process stream or an IES) as the latent heat of liquefaction by melting the material. The energy can be recovered by bringing a process stream in thermal contact, directly or indirectly, with the phase change material and allowing the material to solidify. Through appropriate selection of the phase change material, thermal energy may be stored at any desired temperature. In embodiments, the phase change material may provide process heating at the same temperature as the phase change. For example, sodium nitrite, which has a melting point of approximately 271° C., can be used as a phase change material to store and liberate thermal energy at or near this temperature. Alternatively, boron oxide, which has a melting point of approximately 450° C., can be used as a phase change material to store and liberate thermal energy at or near this higher temperature, which is for example suitable for preheating a gas stream comprising N₂ and H₂ to an appropriate temperature for ammonia synthesis. In embodiments, the phase change material may be melted using electrical heaters or by extracting some heat present in a process stream whenever the IES is available.

Alternatively or additionally, energy can be stored as gravitational potential energy, in embodiments. When renewable energy is available, a mass (e.g., a liquid or solid) can be elevated. At a later time, the elevated mass can be lowered, such that energy is recovered to generate electricity and/or perform mechanical work. In embodiments, the mass is a product or feed. In embodiments, the mass is water.

Alternatively or additionally, energy storage apparatus 50 in FIG. 4 comprises storage batteries kept for intermittency of electric supply.

It is to be understood that intermittency can occur on various time scales, ranging from less than a second (e.g., very short term interruptions in electric supply) to several months (e.g., due to seasonal fluctuations in wind power.) In embodiments, the systems and methods herein relate to diurnal intermittency, that is, daily fluctuations in IES availability due to variations in, for example, solar or wind power. The systems and methods described hereinabove can be applied to intermittency at any time scale. For intermittency on shorter time scales (e.g., seconds, minutes, or a few hours), additional methods and systems as described hereinbelow may be utilized.

In embodiments, one or more reactors are lined with refractory materials or insulated such that brief losses of electric power do not cause a significant drop in a temperature of the one or more refractory lined or insulated reactors. In embodiments, the temperature loss is less than 10° C. for at least 2 minutes, or less than 5° C. for at least 2 minutes, or less than 10° C. for at least 5 minutes, or less than 10° C. for at least 10 minutes, or less than 20° C. for at least 30 minutes.

In embodiments, one or more reactors are built in thermal connection with a body of large thermal mass such that the body is heated during normal operation, but during brief losses of electric power the body can supply heat to the reactor such that there is not a significant drop in a temperature of the reactor. In embodiments, the temperature loss is less than 5° C. for at least 2 minutes, or less than 2° C. for at least 2 minutes, or less than 5° C. for at least 5 minutes, or less than 10° C. for at least 15 minutes, or less than 20° C. for at least 45 minutes.

In embodiments, one or more reactors are in thermal connection with a phase change material chosen such that its melting point is near the desired temperature of the reactor. When the IES is available, this phase change material is kept in the liquid state. When the IES is not available, the cooling and solidification of the phase change material can supply heat to the reactor, such that there is not a significant drop in temperature to the reactor. In embodiments, the temperature loss is less than is less than 4° C. for at least 2 minutes, or less than 5° C. for at least 5 minutes, or less than 5° C. for at least 10 minutes, or less than 10° C. for at least 30 minutes, or less than 20° C. for at least 90 minutes.

Alternatively or additionally, energy storage apparatus 50 comprises backup power for key components (e.g., components such as reactors needed to maintain production of the one or more chemical product or compressors to maintain safe flow of gases). For example, in embodiments, this energy storage apparatus comprises a flywheel. In embodiments, this energy storage apparatus comprises one or more capacitors. In embodiments, this energy storage apparatus comprises chemical batteries for storing electricity. In embodiments, this energy storage apparatus comprises systems utilizing superconductors or supercapacitors. In embodiments, this energy storage apparatus comprises thermal batteries. In embodiments, this energy storage apparatus comprises compressed air or other gases. In embodiments, this energy storage apparatus comprises an appropriate stored fuel and a fuel cell. In embodiments, this energy storage apparatus comprises an appropriate store fuel and a combustor, e.g., a furnace. In embodiments, the stored fuel is derived from renewable or non-fossil fuel based sources.

Alternatively or additionally, the chemical synthesis plant is designed such that, when it is not possible to provide enough stored energy to handle an IES and still operate the entire plant, enough energy is stored to handle some energy needs, and other parts of the plant can be idled until additional energy is available from the IES. In embodiments, when the IES is unavailable, an intermediate product is stored before entering all or part of product purification section 30 of FIG. 3; when the IES is again available, product purification recommences. In embodiments, regeneration, of, for example, driers, adsorbers, and/or catalyst beds, is postponed for when the IES is available. In embodiments, pumping of products to off-site storage or sales is done only when the IES is available. In embodiments, solid handling operations, for example extrusion or bagging, are idled when the IES is unavailable. In embodiments, the chemical synthesis plant is operated at lower throughput (i.e., less feed is processed and less product is produced) until more energy is available.

Alternatively or additionally, it may not be possible to provide enough stored energy to handle the absence of an IES for an extended period of time or for unexpected loss of the IES. In embodiments, enough energy storage is provided (e.g., in energy storage apparatus 50) to allow for safe shutdown of the plant. Safe shutdown can encompass protecting the safety of the plant workers, protecting the physical and mechanical integrity of all plant components, preventing emissions of potentially harmful or regulated substances, avoiding fouling or poisoning of catalysts, solutions, or equipment, allowing for an orderly restart when the IES is available, and/or preventing the waste of valuable feeds, products, or intermediates.

In embodiments, duplicate apparatus or apparatus capable of using multiple energy sources may be utilized to handle an IES. For example, a chemical synthesis plant of this disclosure can comprise compressors driven by steam or gas turbines as a backup for electric motor-driven compressors. In embodiments, non-renewable electricity can be utilized as a back-up for intermittent renewable electricity, for example, to power electric motor-driven compressors when the IES is not available or economical.

In embodiments, some or all of the control system(s) of the plant are integrated with actual and/or predicted cost data for the IES and other energy sources. In embodiments, the operation of the plant, the choice of energy supply, and/or the amount of energy stored are optimized to improve operability, profitability, and safety. In embodiments, this integration and/or optimization can be performed in real-time.

Electrification of the chemical synthesis plant of this disclosure can be provided via an electricity supply that can be high voltage or low voltage. The electric devices can be operable or operated on alternating (single or multiphase) or direct current.

As energy consumption (e.g., to maintain desired temperatures and pressures) represents a large percent of the operating cost for a traditional chemical synthesis plant, increasing energy efficiency (e.g., via electrification) as per this disclosure and/or utilizing one or more components conventionally burned to provide heat and/or burned for compression (e.g., burned in a reactor to maintain a desired operating temperature, burned to produce steam for a steam turbine, and/or burned for a gas turbine) to produce additional chemical product may provide economic advantages over a conventional chemical synthesis plant. In embodiments, aspects of this disclosure (e.g., the elimination of the costly steam system) can serve to reduce the large investment cost required to construct a new chemical facility. Concomitantly, the reduction of the burning of fossil fuels (e.g., natural gas, methane) as a fuel enabled via this disclosure provides for reduced greenhouse gas (GHG) emissions relative to a conventional chemical synthesis plant in which hydrocarbons are burned as fuel. In embodiments, GHG emissions (e.g., carbon dioxide emissions) are reduced by at least 5, 10, 20, 25, 30, 40, 50, 60, 70, 80, 90, 95, 98, or 100% relative to a conventional chemical synthesis plant in which hydrocarbons are burned as fuel. In embodiments, aspects of this disclosure can lead to an increase in carbon efficiency of a process, i.e. to a fraction of carbon consumed in the process that reappears as a useful product, and/or a reduced specific energy consumption (e.g., the energy utilized to synthesize a quantity of chemical product). In embodiments, the specific energy consumption (the net external energy supplied to the process divided by the amount of product produced; also referred to as the net specific energy consumption) is decreased over an otherwise similar conventional process by greater than equal to about 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 95, 98, or 100%.

Conventionally, the energy required for unit operations in chemical processes is generally provided by the burning of fossil fuels, especially natural gas. Herein-disclosed are systems and methods by which this energy input can be reduced or replaced with non-carbon based energy, renewable energy, such as renewable electricity, and/or by electricity from any source (e.g., renewable and/or non-renewable), such that energy efficiency is improved (e.g., energy losses are reduced). The herein-disclosed use of non-carbon based energy, renewable energy, and/or electricity in the production of chemicals can increase energy efficiency of and decrease carbon dioxide emissions from and fossil energy consumption within the chemical synthesis process, and may provide additional feed by reducing or eliminating the burning of a feed component as a fuel.

Via the herein disclosed system and method for providing chemical synthesis via an IES, chemical synthesis can be substantially continuously maintained while utilizing an IES for at least a portion, some, or substantially all of the net energy needed for the chemical synthesis. Various energy storage systems provided herein can be incorporated to produce a chemical via an IES, as per this disclosure, whereby some or substantially all of the net energy needed for the synthesis can be provided by the IES, even during times when the IES is not available.

EXAMPLES

The embodiments having been generally described, the following examples are given as particular embodiments of the disclosure and to demonstrate the practice and advantages thereof. It is understood that the examples are given by way of illustration and are not intended to limit the specification or the claims in any manner.

Example 1: Electrified Olefin Synthesis (e.g., Cracking) Plus PSA

FIG. 6 shows operating parameters for an olefin synthesis process VII electrified as per an embodiment of this disclosure and presented in Examples 1 and 2. The process VII comprises a gas separation unit 260, and the gas separation unit 260 can comprise a pressure swing adsorption (PSA) unit. The gas separation unit 260 is configured to purify the hydrogen- and methane-containing stream 244. Stream 244 has a flowrate of 30.1 t/hr and comprises 48 weight % (88 mol %) hydrogen and 52 weight % (12 mol %) methane. The gas separation unit 260 (e.g., PSA gas separation unit 260) consumes 3 MW of electricity, and yields two product streams, a methane stream 247 consisting essentially of pure methane and a hydrogen stream 248 consisting essentially of pure hydrogen. Via this process VII, an amount of 14.3 t/hr of purified hydrogen produced in PSA 260 can be fed to a fuel cell 270, where the hydrogen is converted to water in water stream 249 and electricity E with an electrical efficiency of 45%, giving continuous production of 253 MW of electricity. The net electricity (250 MW) is used to supply 41% of the 603 MW of electricity required for the process VII.

Example 2: Electrified Olefin Synthesis (e.g., Cracking) Plus PSA and H₂ Compression/Storage

In embodiment, a process VII as described in Example 1 further comprises a hydrogen compression and storage apparatus 280 comprising at least one compressor and storage vessel, and configured to compress and store the resulting 14.3 t/hr of purified hydrogen (which can be introduced thereto via line 248A) for use when the availability of renewable electricity is lower, or when it is more expensive. When needed, the compressed and stored hydrogen can be combined (e.g., via line 248B) with the hydrogen being produced at that time (e.g., the hydrogen in line 248) by the process VII, and both can be converted to electricity using the fuel cell 270. When to use the stored hydrogen for electricity production can be determined by one of skill in the art according to a variety of factors. As one possibility, if some renewable electricity is available on a diurnal basis, 172 tons hydrogen could be collected and stored over a twelve hour period. When released over the next twelve hours and combined with the 14.3 t/hr hydrogen still being produced by the process, this would result in approximately 503 MW of electricity being available continuously for the twelve hours. This could supply 80% of the 603 MW of electricity required for the operation of the process.

Example 3: Electrified Ammonia Synthesis—Electrified Primary (SMR) Reforming Plus PSA

FIG. 7 shows operating parameters for an ammonia synthesis process XII electrified as per an embodiment of this disclosure and presented in Examples 3 and 4. The process XII comprises electric compressors, an electric reformer, and an electric reboiler. As depicted in dashed lines in FIG. 7, a pressure swing adsorption (PSA) gas separation unit 267 is further added to purify the purge gas stream 205′. With a flowrate of 16.7 t/hr, this purge gas stream 205′ contains of 11 weight % hydrogen. The gas separation unit 267 consumes 2 MW of electricity, and yields a product stream 268 of essentially pure hydrogen. The resulting 1.84 t/hr of purified hydrogen is fed to a fuel cell 270, where the hydrogen is converted to water 271 and electricity 272 with an electrical efficiency of 45%, giving continuous production of 33 MW of electricity. The net electricity (31 MW) is used to supply 8.3% of the 375 MW of electricity required for the process XII.

Example 4: Electrified Ammonia Synthesis—Electrified Primary (SMR) Reforming Plus PSA and H₂ Compression/Storage

To the process XII described in Example 3, we further add a pressure swing adsorption (PSA) gas separation unit 267 to purify the purge gas stream 205′. With a flowrate of 16.7 t/hr, this purge gas stream 205′ contains of 11 weight % hydrogen. The gas separation unit 267 consumes 2 MW of electricity, and yields a product stream 268 of essentially pure hydrogen. The resulting 1.84 t/hr of purified hydrogen is compressed by compressor C4 and stored in storage vessel 280 for use when the availability of renewable electricity is lower, or when it is more expensive. When needed, the stored hydrogen in storage vessel 280 is combined with the hydrogen in 268 being produced at that time by the process, and both are converted to electricity 272 using a fuel cell 270. When to use the stored hydrogen for electricity production will be determined by a variety of factors. As one possibility, if some renewable electricity was available on a diurnal basis, 22.1 tons hydrogen could be collected and stored over a twelve hour period. When released over the next twelve hours and combined with the 1.84 t/hr hydrogen in line 268 still being produced by the process, this would result in approximately 64 MW of electricity 272 being available continuously for the twelve hours. This could supply 17% of the 375 MW of electricity required for the operation of the process XII.

Example 5: Electrified Methanol Synthesis Plus PSA

FIG. 8 shows operating parameters for a methanol synthesis process X/XI electrified as per an embodiment of this disclosure and presented in Examples 5 and 6. The process X comprises a pressure swing adsorption (PSA) gas separation unit 295 and a fuel cell 296. The PSA 295 is operable to purify the purge gas stream 205′ and recovers 80% of the 3.37 t/h of hydrogen available. The resulting 2.7 t/h of purified hydrogen 293 is fed to a fuel cell 296, where the hydrogen is converted to water 291 and electricity 296 with an electrical efficiency of 45%, giving continuous production of 48 MW of electricity. This electricity is used to supply approximately 27% of the 180 MW of electricity required for the process X.

Example 6: Electrified Methanol Synthesis Plus PSA and H₂ Compression/Storage

As depicted via dashed lines in FIG. 8, a process XI according to this disclosure comprises a compressor C4 and storage vessel 297. Pressure swing adsorption (PSA) gas separation unit 295 is operable to purify the purge gas stream 205′ and recovers 80% of the 3.37 t/h of hydrogen available. The resulting 2.7 t/h of purified hydrogen 293 is compressed at C4 and stored in storage vessel 297 for use when the availability of renewable electricity is lower, or when it is more expensive. When needed, the stored hydrogen 293A is combined with the hydrogen 293 being produced at that time by the process XI, and both are converted to electricity using the fuel cell 296. When to use the stored hydrogen for electricity production will be determined by a variety of factors, as will be appreciated by those of skill in the art. As one possibility, if some renewable electricity is available on a diurnal basis, 32.4 tons hydrogen could be collected, compressed at C4 and stored at 297 over a twelve hour period. When released over the next twelve hours and combined via stored hydrogen stream 293A with the 2.7 t/h hydrogen 293 still being produced by the process IX, approximately 96 MW of electricity can be available continuously for the twelve hours. This electricity would supply approximately 53% of the 180 MW of electricity required for the operation of the process XI.

While various embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the subject matter disclosed herein are possible and are within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R_(L) and an upper limit, R_(U) is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R_(L)+k*(R_(U)−R_(L)), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc.

Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference is not an admission that it is prior art to the present disclosure, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.

Additional Disclosure Part I

The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. While compositions and methods are described in broader terms of “having”, “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim.

Numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an”, as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents, the definitions that are consistent with this specification should be adopted.

Embodiments disclosed herein include:

A: A chemical synthesis plant comprising: one or more reactors configured for producing, from one or more reactants, a process stream comprising at least one chemical product; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor; and/or a product purification system configured to separate the at least one chemical product from reaction byproducts, unreacted reactants, or a combination thereof within the process stream, wherein the chemical synthesis plant is configured such that a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof utilized via the one or more reactors, the feed preparation system, the product purification system, or a combination thereof is provided from an intermittent energy source (IES).

B: A chemical synthesis plant configured for operation utilizing electricity from a renewable intermittent energy source (IES) to provide a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof.

Each of embodiments A and B may have one or more of the following additional elements: Element 1: further comprising one or more compressors configured for compressing at least one stream comprising the one or more reactants, the at least one chemical products, or at least one intermediate produced by the method, and storage apparatus configured for storing the at least one compressed stream for later use. Element 2: further comprising apparatus for expanding the at least one stored, compressed stream to generate electricity and/or perform mechanical work. Element 3: further comprising cooling apparatus configured for cooling at least one stream selected from the one or more reactants, the at least one chemical product, or at least one intermediate produced by the method, and storage apparatus configured for storing the at least one cooled stream for later use. Element 4: wherein the at least one cooled stream comprises a cryogenic liquid. Element 5: wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a fuel cell for converting at least a portion of the produced hydrogen to electricity. Element 6: further comprising hydrogen storage apparatus for storing at least a portion of the produced hydrogen prior to converting the at least a portion of the produced hydrogen to electricity using the fuel cell when an intermittent electricity source is not available. Element 7: further comprising a compressor upstream of the hydrogen storage apparatus and configured for compressing the hydrogen prior to storing same. Element 8: wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a hydrogen storage apparatus and compressor upstream of the hydrogen storage apparatus and configured for compressing at least a portion of the produced hydrogen prior to storage, and wherein the chemical synthesis plant further comprises a combustion apparatus for combusting a portion of the stored hydrogen to generate steam and/or heat when an intermittent electricity source is not available, and wherein optionally the steam may be used as a reactant or diluent. Element 9: further comprising an apparatus for storing energy via raising a mass in elevation when an intermittent electricity source is available. Element 10: wherein the mass comprises one or more feeds, one or more products, or water. Element 11: wherein one or more reactors are lined with refractory materials such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 10° C. in 2 minutes. Element 12: wherein one or more reactors are thermally connected to a thermal mass such that brief losses of electric power do not cause a significant drop in a temperature of the one or more refractory lined reactors of greater than about 5° C. in 2 minutes. Element 13: wherein one or more reactors are thermally connected to a phase change material such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 4° C. in 2 minutes. Element 14: further comprising apparatus operable for storing heat (e.g., a heated or superheated fluid) for heating one or more process streams when the IES is not available. Element 15: further comprising apparatus configured to utilize liquefaction of a phase change material for storing energy. Element 16: further comprising batteries onsite for handling intermittency of electricity supply. Element 17: further comprising backup power apparatus configured to provide backup power for at least one apparatus of the chemical synthesis plant. Element 18: wherein the backup power apparatus is selected to provide sufficient energy to ensure safe shutdown of the plant. Element 19: wherein the backup power apparatus comprises apparatus driven by compressed gas, a capacitor, a superconductor, a thermal battery and/or a flywheel. Element 20: wherein at least a fraction of the plant operates only when the IES is available. Element 21: configured to be operated at a lower production rate when the IES is unavailable or a reduced amount of the IES is available. Element 22: further comprising a system for receiving information as to energy price and availability, whereby this information can be utilized to optimize energy usage, energy storage, and operation of the plant. Element 23: further comprising: one or more compressors operable for compressing one or more gaseous feed streams for storage when the IES is available and/or below a threshold price, such that at least a portion of the compressed one or more feed streams can be utilized as a feed stream and/or to provide electricity and/or mechanical work when the IES is not available and/or is above a threshold price. Element 24: wherein the one or more compressors are to compress and liquefy the one or more gaseous feed streams when electricity from the IES is available and/or below a threshold price, and wherein the system further comprises apparatus operable to vaporize and expand the liquefied one or more gaseous feed streams to generate electricity, perform mechanical work, and/or to provide feed when the IES is not readily available and/or is above a threshold price. Element 25: further comprising one or more chillers configured to chill one or more feed streams, product streams, and/or another fluid, and storage apparatus configured for storage of the chilled one or more feed streams, product streams and/or another fluid for use as a refrigerant when the IES is not available and/or is above a threshold price. Element 26: wherein the refrigerant comprises methane, ethane, propane, butane, pentane, ethylene, propylene, ammonia, nitrogen, or a combination thereof. Element 27: further comprising a fuel cell and apparatus for storing hydrogen, whereby hydrogen can be stored in the storage apparatus and the stored hydrogen introduced into the fuel cell to generate electricity to handle intermittency of electric supply from the IES. Element 28: further comprising an air separation unit (ASU) configured to generate oxygen and nitrogen, storage apparatus configured for storing at least a portion of the generated oxygen and/or nitrogen under pressure, and an expander, such that the pressurized stored oxygen and/or nitrogen can be utilized as a reactant and/or for the generation of electricity via expansion in the expander when the IES is not available and/or is above a threshold price. Element 29: further comprising one or more duplicate apparatus operable to handle availability of the IES. Element 30: wherein the one or more duplicate apparatus comprise one or more compressors driven by steam or gas turbines utilized as a backup for one or more electric motor-driven compressors. Element 31: wherein the plant consumes an average daily amount of at least 25 MW for the heating, cooling, compressing, or a combination thereof. Element 32: wherein the amount of CO₂ emitted is at least 10% less than a similar plant configured for operation without utilizing electricity from an IES. Element 33: wherein the specific energy consumption is at least 10% less than a similar plant configured for operation without utilizing electricity from an IES.

Additional Disclosure Part II

The following are non-limiting, specific embodiments in accordance with the present disclosure:

A first embodiment, which is a chemical synthesis plant comprising one or more reactors configured for producing, from one or more reactants, a process stream comprising at least one chemical product, a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor, and/or a product purification system configured to separate the at least one chemical product from reaction byproducts, unreacted reactants, or a combination thereof within the process stream, wherein the chemical synthesis plant is configured such that a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof utilized via the one or more reactors, the feed preparation system, the product purification system, or a combination thereof is provided from an intermittent energy source (IES).

A second embodiment, which is the chemical synthesis plant of the first embodiment, further comprising one or more compressors configured for compressing at least one stream comprising the one or more reactants, the at least one chemical products, or at least one intermediate produced by the method, and storage apparatus configured for storing the at least one compressed stream for later use.

A third embodiment, which is the chemical synthesis plant of the second embodiment, further comprising apparatus for expanding the at least one stored, compressed stream to generate electricity and/or perform mechanical work.

A fourth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising cooling apparatus configured for cooling at least one stream selected from the one or more reactants, the at least one chemical product, or at least one intermediate produced by the method, and storage apparatus configured for storing the at least one cooled stream for later use.

A fifth embodiment, which is the chemical synthesis plant of the fourth embodiment, wherein the at least one cooled stream comprises a cryogenic liquid.

A sixth embodiment, which is the chemical synthesis plant of the first embodiment, wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a fuel cell for converting at least a portion of the produced hydrogen to electricity.

A seventh embodiment, which is the chemical synthesis plant of the sixth embodiment further comprising hydrogen storage apparatus for storing at least a portion of the produced hydrogen prior to converting the at least a portion of the produced hydrogen to electricity using the fuel cell when an intermittent electricity source is not available.

An eighth embodiment, which is the chemical synthesis plant of the seventh embodiment, further comprising a compressor upstream of the hydrogen storage apparatus and configured for compressing the hydrogen prior to storing same.

A ninth embodiment, which is the chemical synthesis plant of the first embodiment, wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a hydrogen storage apparatus and compressor upstream of the hydrogen storage apparatus and configured for compressing at least a portion of the produced hydrogen prior to storage, and wherein the chemical synthesis plant further comprises a combustion apparatus for combusting a portion of the stored hydrogen to generate steam and/or heat when an intermittent electricity source is not available, and wherein optionally the steam may be used as a reactant or diluent.

A tenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising an apparatus for storing energy via raising a mass in elevation when an intermittent electricity source is available.

An eleventh embodiment, which is the chemical synthesis plant of the tenth embodiment, wherein the mass comprises one or more feeds, one or more products, or water.

A twelfth embodiment, which is the chemical synthesis plant of the first embodiment, wherein one or more reactors are lined with refractory materials such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 10° C. in 2 minutes.

A thirteenth embodiment, which is the chemical synthesis plant of the first embodiment, wherein one or more reactors are thermally connected to a thermal mass such that brief losses of electric power do not cause a significant drop in a temperature of the one or more refractory lined reactors of greater than about 5° C. in 2 minutes.

A fourteenth embodiment, which is the chemical synthesis plant of the first embodiment, wherein one or more reactors are thermally connected to a phase change material such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 4° C. in 2 minutes.

A fifteenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising apparatus operable for storing heat (e.g., a heated or superheated fluid) for heating one or more process streams when the IES is not available.

A sixteenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising apparatus configured to utilize liquefaction of a phase change material for storing energy.

A seventeenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising batteries onsite for handling intermittency of electricity supply.

An eighteenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising backup power apparatus configured to provide backup power for at least one apparatus of the chemical synthesis plant.

A nineteenth embodiment, which is the chemical synthesis plant of the eighteenth embodiment, wherein the backup power apparatus is selected to provide sufficient energy to ensure safe shutdown of the plant.

A twentieth embodiment, which is the chemical synthesis plant of the eighteenth embodiment, wherein the backup power apparatus comprises apparatus driven by compressed gas, a capacitor, a superconductor, a thermal battery and/or a flywheel.

A twenty-first embodiment, which is the chemical synthesis plant of the first embodiment, wherein at least a fraction of the plant operates only when the IES is available.

A twenty-second embodiment, which is the chemical synthesis plant of the first embodiment, configured to be operated at a lower production rate when the IES is unavailable or a reduced amount of the IES is available.

A twenty-third embodiment, which is the chemical synthesis plant of the first embodiment, further comprising a system for receiving information as to energy price and availability, whereby this information can be utilized to optimize energy usage, energy storage, and operation of the plant.

A twenty-fourth embodiment, which is a chemical synthesis plant configured for operation utilizing electricity from a renewable intermittent energy source (IES) to provide a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof.

A twenty-fifth embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising one or more compressors operable for compressing one or more gaseous feed streams for storage when the IES is available and/or below a threshold price, such that at least a portion of the compressed one or more feed streams can be utilized as a feed stream and/or to provide electricity and/or mechanical work when the IES is not available and/or is above a threshold price.

A twenty-sixth embodiment, which is the chemical synthesis plant of the twenty-fifth embodiment, wherein the one or more compressors are to compress and liquefy the one or more gaseous feed streams when electricity from the IES is available and/or below a threshold price, and wherein the system further comprises apparatus operable to vaporize and expand the liquefied one or more gaseous feed streams to generate electricity, perform mechanical work, and/or to provide feed when the IES is not readily available and/or is above a threshold price.

A twenty-seventh embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising one or more chillers configured to chill one or more feed streams, product streams, and/or another fluid, and storage apparatus configured for storage of the chilled one or more feed streams, product streams and/or another fluid for use as a refrigerant when the IES is not available and/or is above a threshold price.

A twenty-eighth embodiment, which is the chemical synthesis plant of the twenty-seventh embodiment, wherein the refrigerant comprises methane, ethane, propane, butane, pentane, ethylene, propylene, ammonia, nitrogen, or a combination thereof.

A twenty-ninth embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising a fuel cell and apparatus for storing hydrogen, whereby hydrogen can be stored in the storage apparatus and the stored hydrogen introduced into the fuel cell to generate electricity to handle intermittency of electric supply from the IES.

A thirtieth embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising an air separation unit (ASU) configured to generate oxygen and nitrogen, storage apparatus configured for storing at least a portion of the generated oxygen and/or nitrogen under pressure, and an expander, such that the pressurized stored oxygen and/or nitrogen can be utilized as a reactant and/or for the generation of electricity via expansion in the expander when the IES is not available and/or is above a threshold price.

A thirty-first embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising one or more duplicate apparatus operable to handle availability of the IES.

A thirty-second embodiment, which is the chemical synthesis plant of the thirty-first embodiment, wherein the one or more duplicate apparatus comprise one or more compressors driven by steam or gas turbines utilized as a backup for one or more electric motor-driven compressors.

A thirty-third embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, wherein the plant consumes an average daily amount of at least 25 MW for the heating, cooling, compressing, or a combination thereof.

A thirty-fourth embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, wherein the amount of CO₂ emitted is at least 10% less than a similar plant configured for operation without utilizing electricity from an IES.

A thirty-fifth embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, wherein the specific energy consumption is at least 10% less than a similar plant configured for operation without utilizing electricity from an IES.

A thirty-sixth embodiment, which is a chemical synthesis plant operable with an intermittent energy supply (IES) as described herein.

Additional Disclosure Part III

The following are non-limiting, specific embodiments in accordance with the present disclosure:

Embodiments disclosed herein include:

A: A method of producing one or more chemical products, the method comprising: preparing one or more feed streams comprising one or more reactants for introduction into a reactor; reacting the one or more reactants in the reactor to produce a product stream comprising the one or more chemical products; separating the one or more chemical products from reaction byproducts, unreacted reactants, or a combination thereof within the product stream; and/or recycling one or more of the unreacted reactants and/or reaction byproducts; and providing a majority (e.g., greater than 50, 60, 70, 80, or 90%) of the net energy needed for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of the preparing, the reacting, the separating, the recycling, or a combination thereof by electricity produced from an renewable intermittent energy source (IES) when the renewable intermittent energy source (IES) is available.

B: A method of operating, designing, and/or retrofitting a chemical synthesis plant, the method comprising: utilizing electricity from a renewable intermittent energy source (IES) to provide a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof when the renewable IES is available and/or below a threshold price.

Each of embodiments A and B may have one or more of the following additional elements: Element 1: further comprising compressing at least one stream selected from the one or more feed streams, the one or more chemical products, or at least one intermediate produced by the method, and storing the at least one compressed stream for later use. Element 2: further comprising expanding the at least one stored, compressed stream to generate electricity or perform mechanical work. Element 3: further comprising cooling at least one stream selected from the one or more feed streams, the one or more chemical products, or at least one intermediate produced by the method, and storing the at least one cooled stream for later use. Element 4: wherein the at least one cooled stream comprises a cryogenic liquid. Element 5: wherein the later use comprises use as a refrigerant. Element 6: wherein the preparing, the reacting, the separating, or a combination thereof produces hydrogen, and wherein the method further comprises converting at least a portion of the produced hydrogen to electricity using a fuel cell. Element 7: further comprising storing at least a portion of the produced hydrogen prior to converting the at least a portion of the produced hydrogen to electricity using the fuel cell when an intermittent electricity source is not available. Element 8: further comprising compressing the hydrogen prior to storing same. Element 9: further comprising combusting at least a portion of the stored hydrogen to generate steam and heat when an intermittent electricity source is not available, and optionally utilizing the steam as a reactant or diluent. Element 10: further comprising storing energy by raising a mass in elevation when an intermittent electricity source is available. Element 11: wherein the mass comprises one or more feeds, one or more products, or water. Element 12: wherein one or more reactors are lined with refractory materials such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than 10° C. in 2 minutes. Element 13: further comprising adjusting an inlet pressure of at least one of the one or more feed streams with a concomitant production of electricity. Element 14: further comprising thermally connecting one or more reactors to a thermal mass such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 5° C. in 2 minutes. Element 15: further comprising thermally connecting one or more reactors to a phase change material such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 4° C. in 2 minutes. Element 16: further comprising storing heat (e.g., a heated or superheated fluid) for heating one or more process streams when electrical heating with electricity from the IES is not available. Element 17: further comprising utilizing the liquefaction of a phase change material for storing energy. Element 18: further comprising storing batteries onsite for intermittency of electricity supply from the IES. Element 19: further comprising providing backup power for at least one apparatus. Element 20: wherein the backup power apparatus is selected to provide sufficient energy to ensure safe shutdown of the plant. Element 21: comprising providing backup power via an apparatus driven by compressed gas, a capacitor, a superconductor, a thermal battery and/or a flywheel. Element 22: further comprising operating at least a fraction of the plant only when the IES is available. Element 23: further comprising operating at a lower production rate when the IES is unavailable or a reduced amount of the IES is available. Element 24: further receiving information as to energy price and availability, and utilizing the information to optimize energy usage, energy storage, and/or production of the one or more chemical products. Element 25: further comprising: compressing one or more gaseous process streams for storage when the renewable IES is available and/or below a threshold price and utilizing at least a portion of the compressed one or more feed streams as a feed stream and/or to provide electricity and/or mechanical work when the renewable IES is not available and/or is above a threshold price. Element 26: wherein the one or more gaseous process streams are compressed and stored at a pressure greater than a process operating pressure, and further comprising generating electricity from a reduction in pressure from the pressure greater than the process operating pressure to the operating pressure. Element 27: wherein the one or more gaseous process streams are compressed and liquefied when electricity from the renewable IES is available and/or below a threshold price, and vaporized and expanded to generate electricity, perform mechanical work, and/or to provide feed when electricity from the renewable IES is not readily available and/or is above a threshold price. Element 28: further comprising chilling and storing the product stream and/or the one or more process streams for use as a refrigerant for intermittency of electric supply from the renewable IES. Element 29: wherein the product stream and/or the one or more process streams comprise methane, ethane, propane, ethylene, propylene, ammonia, or a combination thereof. Element 30: wherein the product stream and/or the one or more process streams are chilled and stored when electricity from the renewable IES is readily available and/or below a threshold price and used to cool one or more other process streams when electricity from the renewable IES is not available and/or or is above a threshold price, thus producing one or more warmer liquid and/or gas streams. Element 31: further comprising utilizing the one or more warmer liquid and/or gas streams obtained by cooling the product stream and/or the one or more other process streams as a feed and/or withdrawing same as a product. Element 32: further comprising storing hydrogen, and passing stored hydrogen through a fuel cell to generate electricity to handle intermittency of electric supply from the renewable IES. Element 33: further comprising generating oxygen and nitrogen in an air separation plant, storing at least a portion of the generated oxygen and/or nitrogen under pressure, and utilizing the pressurized stored oxygen and/or nitrogen as a reactant and/or for the generation of electricity via expansion when the renewable IES is not available and/or is above a threshold price. Element 34: further comprising utilizing one or more duplicate apparatus to handle availability of electricity from the renewable IES. Element 35: wherein the duplicate apparatus comprise one or more compressors driven by steam or gas turbines utilized as a backup for one or more electric motor-driven compressors. Element 36: further comprising utilizing non-renewable electricity as a back-up for electricity from the renewable IES when the renewable IES is not available and/or is above a threshold price. Element 37: further comprising powering electric motor-driven compressors with electricity from the renewable IES, when available or below a threshold price, and with non-renewable electricity when the renewable IES is not available and/or above a threshold price. Element 38: further comprising consuming an average daily amount of at least 25 MW for the heating, cooling, compressing, or a combination thereof.

Additional Disclosure Part IV

The following are non-limiting, specific embodiments in accordance with the present disclosure:

A first embodiment, which is a method of producing one or more chemical products, the method comprising preparing one or more feed streams comprising one or more reactants for introduction into a reactor, reacting the one or more reactants in the reactor to produce a product stream comprising the one or more chemical products, separating the one or more chemical products from reaction byproducts, unreacted reactants, or a combination thereof within the product stream, and/or recycling one or more of the unreacted reactants and/or reaction byproducts, and providing a majority (e.g., greater than 50, 60, 70, 80, or 90%) of the net energy needed for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of the preparing, the reacting, the separating, the recycling, or a combination thereof by electricity produced from an renewable intermittent energy source (IES) when the renewable intermittent energy source (IES) is available.

A second embodiment, which is the method of the first embodiment further comprising compressing at least one stream selected from the one or more feed streams, the one or more chemical products, or at least one intermediate produced by the method, and storing the at least one compressed stream for later use.

A third embodiment, which is the method of the second embodiment further comprising expanding the at least one stored, compressed stream to generate electricity or perform mechanical work.

A fourth embodiment, which is the method of the first embodiment further comprising cooling at least one stream selected from the one or more feed streams, the one or more chemical products, or at least one intermediate produced by the method, and storing the at least one cooled stream for later use.

A fifth embodiment, which is the method of the fourth embodiment, wherein the at least one cooled stream comprises a cryogenic liquid.

A sixth embodiment, which is the method of the fourth embodiment, wherein the later use comprises use as a refrigerant.

A seventh embodiment, which is the method of the first embodiment, wherein the preparing, the reacting, the separating, or a combination thereof produces hydrogen, and wherein the method further comprises converting at least a portion of the produced hydrogen to electricity using a fuel cell.

An eighth embodiment, which is the method of the seventh embodiment further comprising storing at least a portion of the produced hydrogen prior to converting the at least a portion of the produced hydrogen to electricity using the fuel cell when an intermittent electricity source is not available.

A ninth embodiment, which is the method of the seventh embodiment further comprising compressing the hydrogen prior to storing same.

A tenth embodiment, which is the method of the seventh embodiment further comprising combusting at least a portion of the stored hydrogen to generate steam and heat when an intermittent electricity source is not available, and optionally utilizing the steam as a reactant or diluent.

An eleventh embodiment, which is the method of the first embodiment further comprising storing energy by raising a mass in elevation when an intermittent electricity source is available.

A twelfth embodiment, which is the method of the eleventh embodiment, wherein the mass comprises one or more feeds, one or more products, or water.

A thirteenth embodiment, which is the method of the first embodiment, wherein one or more reactors are lined with refractory materials such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than 10° C. in 2 minutes.

A fourteenth embodiment, which is the method of the first embodiment further comprising adjusting an inlet pressure of at least one of the one or more feed streams with a concomitant production of electricity.

A fifteenth embodiment, which is the method of the first embodiment further comprising thermally connecting one or more reactors to a thermal mass such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 5° C. in 2 minutes.

A sixteenth embodiment, which is the method of the first embodiment further comprising thermally connecting one or more reactors to a phase change material such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 4° C. in 2 minutes.

A seventeenth embodiment, which is the method of the first embodiment further comprising storing heat (e.g., a heated or superheated fluid) for heating one or more process streams when electrical heating with electricity from the IES is not available.

An eighteenth embodiment, which is the method of the first embodiment further comprising utilizing the liquefaction of a phase change material for storing energy.

A nineteenth embodiment, which is the method of the first embodiment further comprising storing batteries onsite for intermittency of electricity supply from the IES.

A twentieth embodiment, which is the method of the first embodiment further comprising providing backup power for at least one apparatus.

A twenty-first embodiment, which is the method of the twentieth embodiment, wherein the backup power apparatus is selected to provide sufficient energy to ensure safe shutdown of the plant.

A twenty-second embodiment, which is the method of the twentieth embodiment comprising providing backup power via an apparatus driven by compressed gas, a capacitor, a superconductor, a thermal battery and/or a flywheel.

A twenty-third embodiment, which is the method of the first embodiment further comprising operating at least a fraction of the plant only when the IES is available.

A twenty-fourth embodiment, which is the method of the first embodiment further comprising operating at a lower production rate when the IES is unavailable or a reduced amount of the IES is available.

A twenty-fifth embodiment, which is the method of the first embodiment further comprising receiving information as to energy price and availability, and utilizing the information to optimize energy usage, energy storage, and/or production of the one or more chemical products.

A twenty-sixth embodiment, which is a method of operating, designing, and/or retrofitting a chemical synthesis plant, the method comprising utilizing electricity from a renewable intermittent energy source (IES) to provide a majority (e.g., greater than 50, 60, 70, 80, 90, or 100%) of the net energy needed for heating, cooling, compressing, or a combination thereof when the renewable IES is available and/or below a threshold price.

A twenty-seventh embodiment, which is the method of the twenty-sixth embodiment further comprising compressing one or more gaseous process streams for storage when the renewable IES is available and/or below a threshold price and utilizing at least a portion of the compressed one or more feed streams as a feed stream and/or to provide electricity and/or mechanical work when the renewable IES is not available and/or is above a threshold price.

A twenty-eighth embodiment, which is the method of the twenty-seventh embodiment, wherein the one or more gaseous process streams are compressed and stored at a pressure greater than a process operating pressure, and further comprising generating electricity from a reduction in pressure from the pressure greater than the process operating pressure to the operating pressure.

A twenty-ninth embodiment, which is the method of the twenty-seventh embodiment, wherein the one or more gaseous process streams are compressed and liquefied when electricity from the renewable IES is available and/or below a threshold price, and vaporized and expanded to generate electricity, perform mechanical work, and/or to provide feed when electricity from the renewable IES is not readily available and/or is above a threshold price.

A thirtieth embodiment, which is the method of the twenty-sixth embodiment further comprising chilling and storing the product stream and/or the one or more process streams for use as a refrigerant for intermittency of electric supply from the renewable IES.

A thirty-first embodiment, which is the method of the thirtieth embodiment, wherein the product stream and/or the one or more process streams comprise methane, ethane, propane, ethylene, propylene, ammonia, or a combination thereof.

A thirty-second embodiment, which is the method of the thirtieth embodiment, wherein the product stream and/or the one or more process streams are chilled and stored when electricity from the renewable IES is readily available and/or below a threshold price and used to cool one or more other process streams when electricity from the renewable IES is not available and/or or is above a threshold price, thus producing one or more warmer liquid and/or gas streams.

A thirty-third embodiment, which is the method of the thirty-second embodiment further comprising utilizing the one or more warmer liquid and/or gas streams obtained by cooling the product stream and/or the one or more other process streams as a feed and/or withdrawing same as a product.

A thirty-fourth embodiment, which is the method of the twenty-sixth embodiment further comprising storing hydrogen, and passing stored hydrogen through a fuel cell to generate electricity to handle intermittency of electric supply from the renewable IES.

A thirty-fifth embodiment, which is the method of the twenty-sixth embodiment further comprising generating oxygen and nitrogen in an air separation plant, storing at least a portion of the generated oxygen and/or nitrogen under pressure, and utilizing the pressurized stored oxygen and/or nitrogen as a reactant and/or for the generation of electricity via expansion when the renewable IES is not available and/or is above a threshold price.

A thirty-sixth embodiment, which is the method of the twenty-sixth embodiment further comprising utilizing one or more duplicate apparatus to handle availability of electricity from the renewable IES.

A thirty-seventh embodiment, which is the method of the thirty-sixth embodiment, wherein the duplicate apparatus comprise one or more compressors driven by steam or gas turbines utilized as a backup for one or more electric motor-driven compressors.

A thirty-eighth embodiment, which is the method of the twenty-sixth embodiment further comprising utilizing non-renewable electricity as a back-up for electricity from the renewable IES when the renewable IES is not available and/or is above a threshold price.

A thirty-ninth embodiment, which is the method of the thirty-eighth embodiment further comprising powering electric motor-driven compressors with electricity from the renewable IES, when available or below a threshold price, and with non-renewable electricity when the renewable IES is not available and/or above a threshold price.

A fortieth embodiment, which is the method of the twenty-sixth embodiment further comprising consuming an average daily amount of at least 25 MW for the heating, cooling, compressing, or a combination thereof.

A forty-first embodiment, which is a method of operating a chemical process as described herein.

Additional Disclosure Part V

The following are non-limiting, specific embodiments in accordance with the present disclosure:

A first embodiment, which is a chemical synthesis plant comprising one or more reactors configured for producing, from one or more reactants, a process stream comprising at least one chemical product, a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor, and a product purification system configured to separate the at least one chemical product from reaction byproducts, unreacted reactants, or a combination thereof within the process stream, wherein the chemical synthesis plant is configured such that at least 50% of the net energy needed for heating, cooling, compressing, or a combination thereof utilized via the one or more reactors, the feed preparation system, the product purification system, or a combination thereof is provided from an intermittent energy source (IES), and wherein the plant consumes an average daily amount of at least 25 MW of electricity for the heating, cooling, compressing, or a combination thereof.

A second embodiment, which is the chemical synthesis plant according to the first embodiment, wherein the chemical synthesis plant does not include a flue gas heat recovery section.

A third embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising one or more compressors configured for compressing at least one stream comprising the one or more reactants, the at least one chemical products, or at least one intermediate produced by the method, storage apparatus configured for storing the at least one compressed stream for later use, and further comprising apparatus for expanding the at least one stored, compressed stream to generate electricity or perform mechanical work.

A fourth embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising cooling apparatus configured for cooling at least one stream selected from the one or more reactants, the at least one chemical product, or at least one intermediate produced by the method, and storage apparatus configured for storing the at least one cooled stream for later use, and wherein the at least one cooled stream comprises a cryogenic liquid.

A fifth embodiment, which is the chemical synthesis plant according to the first embodiment, wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a fuel cell for converting at least a portion of the produced hydrogen to electricity, the chemical synthesis plant further comprising hydrogen storage apparatus for storing at least a portion of the produced hydrogen prior to converting the at least a portion of the produced hydrogen to electricity using the fuel cell when an intermittent electricity source is not available, and further comprising a compressor upstream of the hydrogen storage apparatus and configured for compressing the hydrogen prior to storing same.

A sixth embodiment, which is the chemical synthesis plant according to the first embodiment, wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a hydrogen storage apparatus and compressor upstream of the hydrogen storage apparatus and configured for compressing at least a portion of the produced hydrogen prior to storage, and wherein the chemical synthesis plant further comprises a combustion apparatus for combusting a portion of the stored hydrogen to generate steam or heat when an intermittent electricity source is not available, and wherein the steam is used as a reactant or diluent.

A seventh embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising an apparatus for storing energy via raising a mass in elevation when an intermittent electricity source is available, wherein the mass comprises one or more feeds, one or more products, or water.

An eighth embodiment, which is the chemical synthesis plant according to the first embodiment, wherein one or more reactors are lined with refractory materials such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 10° C. in 2 minutes.

A ninth embodiment, which is the chemical synthesis plant according to the first embodiment, wherein one or more reactors are thermally connected to a thermal mass such that brief losses of electric power do not cause a significant drop in a temperature of the one or more refractory lined reactors of greater than about 5° C. in 2 minutes.

A tenth embodiment, which is the chemical synthesis plant according to the first embodiment, wherein one or more reactors are thermally connected to a phase change material such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 4° C. in 2 minutes.

An eleventh embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising apparatus operable for storing heat as a heated or superheated fluid for heating one or more process streams when the IES is not available.

A twelfth embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising apparatus configured to utilize liquefaction of a phase change material for storing energy.

A thirteenth embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising backup power apparatus configured to provide backup power for at least one apparatus of the chemical synthesis plant, wherein the backup power apparatus is selected to provide sufficient energy to ensure safe shutdown of the plant, and wherein the backup power apparatus comprises apparatus driven by compressed gas, a capacitor, a superconductor, a thermal battery and/or a flywheel.

A fourteenth embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising a system for receiving information as to energy price and availability, whereby this information can be utilized to optimize energy usage, energy storage, and operation of the plant.

A fifteenth embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising an air separation unit (ASU) configured to generate oxygen and nitrogen, storage apparatus configured for storing at least a portion of the generated oxygen and/or nitrogen under pressure, and an expander, such that the pressurized stored oxygen and/or nitrogen can be utilized as a reactant and/or for the generation of electricity via expansion in the expander when the IES is not available and/or is above a threshold price.

A sixteenth embodiment, which is a method of producing one or more chemical products, the method comprising preparing one or more feed streams comprising one or more reactants for introduction into a reactor, reacting the one or more reactants in the reactor to produce a product stream comprising the one or more chemical products, separating the one or more chemical products from reaction byproducts, unreacted reactants, or a combination thereof within the product stream, recycling one or more of the unreacted reactants and/or reaction byproducts, and providing at least 50% of the net energy needed for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of the preparing, the reacting, the separating, the recycling, or a combination thereof by electricity produced from an renewable intermittent energy source (IES) when the renewable intermittent energy source (IES) is available, and wherein the plant consumes an average daily amount of at least 25 MW of electricity for the heating, cooling, compressing, or a combination thereof.

While preferred embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention.

Numerous other modifications, equivalents, and alternatives, will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such modifications, equivalents, and alternatives where applicable. Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present invention. Thus, the claims are a further description and are an addition to the detailed description of the present invention. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference. 

What is claimed is:
 1. A chemical synthesis plant comprising: one or more reactors configured for producing, from one or more reactants, a process stream comprising at least one chemical product; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor; and a product purification system configured to separate the at least one chemical product from reaction byproducts, unreacted reactants, or a combination thereof within the process stream, wherein the chemical synthesis plant is configured such that at least 50% of the net energy needed for heating, cooling, compressing, or a combination thereof utilized via the one or more reactors, the feed preparation system, the product purification system, or a combination thereof is provided from an intermittent energy source (IES), and wherein the plant consumes an average daily amount of at least 25 MW of electricity for the heating, cooling, compressing, or a combination thereof.
 2. The chemical synthesis plant according to claim 1, wherein the chemical synthesis plant does not include a flue gas heat recovery section.
 3. The chemical synthesis plant according to claim 1, further comprising: one or more compressors configured for compressing at least one stream comprising the one or more reactants, the at least one chemical products, or at least one intermediate produced by the method; storage apparatus configured for storing the at least one compressed stream for later use; and further comprising apparatus for expanding the at least one stored, compressed stream to generate electricity or perform mechanical work.
 4. The chemical synthesis plant according to claim 1, further comprising: cooling apparatus configured for cooling at least one stream selected from the one or more reactants, the at least one chemical product, or at least one intermediate produced by the method; and storage apparatus configured for storing the at least one cooled stream for later use, and wherein the at least one cooled stream comprises a cryogenic liquid.
 5. The chemical synthesis plant according to claim 1, wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a fuel cell for converting at least a portion of the produced hydrogen to electricity, the chemical synthesis plant further comprising hydrogen storage apparatus for storing at least a portion of the produced hydrogen prior to converting the at least a portion of the produced hydrogen to electricity using the fuel cell when an intermittent electricity source is not available, and further comprising a compressor upstream of the hydrogen storage apparatus and configured for compressing the hydrogen prior to storing same.
 6. The chemical synthesis plant according to claim 1, wherein the one or more reactors, the feed preparation system, the product purification system, or the combination thereof is configured for the production of hydrogen, and wherein the chemical synthesis plant further comprises a hydrogen storage apparatus and compressor upstream of the hydrogen storage apparatus and configured for compressing at least a portion of the produced hydrogen prior to storage, and wherein the chemical synthesis plant further comprises a combustion apparatus for combusting a portion of the stored hydrogen to generate steam or heat when an intermittent electricity source is not available, and wherein the steam is used as a reactant or diluent.
 7. The chemical synthesis plant according to claim 1, further comprising an apparatus for storing energy via raising a mass in elevation when an intermittent electricity source is available, wherein the mass comprises one or more feeds, one or more products, or water.
 8. The chemical synthesis plant according to claim 1, wherein one or more reactors are lined with refractory materials such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 10° C. in 2 minutes.
 9. The chemical synthesis plant according to claim 1, wherein one or more reactors are thermally connected to a thermal mass such that brief losses of electric power do not cause a significant drop in a temperature of the one or more refractory lined reactors of greater than about 5° C. in 2 minutes.
 10. The chemical synthesis plant according to claim 1, wherein one or more reactors are thermally connected to a phase change material such that brief losses of electric power do not cause a drop in a temperature of the one or more refractory lined reactors of greater than about 4° C. in 2 minutes.
 11. The chemical synthesis plant according to claim 1, further comprising apparatus operable for storing heat as a heated or superheated fluid for heating one or more process streams when the IES is not available.
 12. The chemical synthesis plant according to claim 1, further comprising apparatus configured to utilize liquefaction of a phase change material for storing energy.
 13. The chemical synthesis plant according to claim 1, further comprising backup power apparatus configured to provide backup power for at least one apparatus of the chemical synthesis plant, wherein the backup power apparatus is selected to provide sufficient energy to ensure safe shutdown of the plant, and wherein the backup power apparatus comprises apparatus driven by compressed gas, a capacitor, a superconductor, a thermal battery and/or a flywheel.
 14. The chemical synthesis plant according to claim 1, further comprising a system for receiving information as to energy price and availability, whereby this information can be utilized to optimize energy usage, energy storage, and operation of the plant.
 15. The chemical synthesis plant according to claim 1, further comprising an air separation unit (ASU) configured to generate oxygen and nitrogen, storage apparatus configured for storing at least a portion of the generated oxygen and/or nitrogen under pressure, and an expander, such that the pressurized stored oxygen and/or nitrogen can be utilized as a reactant and/or for the generation of electricity via expansion in the expander when the IES is not available and/or is above a threshold price.
 16. A method of producing one or more chemical products, the method comprising: preparing one or more feed streams comprising one or more reactants for introduction into a reactor; reacting the one or more reactants in the reactor to produce a product stream comprising the one or more chemical products; separating the one or more chemical products from reaction byproducts, unreacted reactants, or a combination thereof within the product stream; recycling one or more of the unreacted reactants and/or reaction byproducts; and providing at least 50% of the net energy needed for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of the preparing, the reacting, the separating, the recycling, or a combination thereof by electricity produced from an renewable intermittent energy source (IES) when the renewable intermittent energy source (IES) is available, and wherein the plant consumes an average daily amount of at least 25 MW of electricity for the heating, cooling, compressing, or a combination thereof. 